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Download Stylus Pro 4000 Field Repair Guide
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Stylus Pro 4000 Field Repair Guide 4/28/05 Table of Contents Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 12 Carriage Removal Procedure - - - Cartridge Release Lever Repair - - Cartridge Release Sensor Repair - Damper Removal - - - - - - - - - Ink Bay Removal (Left) - - - - - - - Ink Bay Removal (Right) - - - - - - Input Roller Assembly, Disassembly Input Roller Assembly, Re-assembly Input Roller Assembly Removal - - Main Board Replacement - - - - - Paper Exit Roller Removal - - - - - Plastic Roller Upgrade - - - - - - - Print Head Replacement Procedure Pump and Cap Installation - - - - - Pump and Cap Removal - - - - - - Side Cover Removal (Left) - - - - - Side Cover Removal (Right) - - - - Top Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 - 16 - 17 - 18 - 26 - 31 - 36 - 41 - 46 - 51 - 58 - 61 - 80 - 87 - 93 - 98 - 99 - 101 Error Codes (Maintenance) Error Codes (Service) - - 00000088 - - - - - - - - - 00000101 - - - - - - - - - 00000103 - - - - - - - - - 00000105 - - - - - - - - - 00010000 - 00010003 - - - Color Shift - - - - - - - - Command Error - - - - - Communication Errors PC Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 - 104 - 107 - 108 - 109 - 110 - 111 - 112 - 113 - 114 - 116 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102 - - - - - Printer Component, Software Item, LCD Display, Printer Button Page 1. Stylus Pro 4000 Field Repair Guide Adjustments 4/28/05 Drop of Ink - - - - - - - - - - - - - Grainy or Ghosting - - - - - - - - Horizontal Banding - - - - - - - - Missing Nozzle Diagnosis and Repair Paper Jam Errors - - - - - - - - - Paper Not Cut - - - - - - - - - - - Reload Paper - - - - - - - - - - - Random Nozzles - - - - - - - - - - Scratch - - - - - - - - - - - - - - - Set Ink Cartridges - - - - - - - - - Set Ink Lever - - - - - - - - - - - - Smudge - - - - - - - - - - - - - - Smear - - - - - - - - - - - - - - - Vertical Banding - - - - - - - - - - Wrong Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 - 118 - 119 - 121 - 124 - 125 - 126 - 128 - 129 - 130 - 131 - 132 - 133 - 134 - 135 1000mm Feed Adjustment - - - - - - - - - - - Auto Bi-D Adjustment [PG 1.2] - - - - - - - - Auto Uni-D Adjustment - - - - - - - - - - - - Carriage Timing Belt Tension Adjustment - - - Change Model Name - - - - - - - - - - - - - - Check Nozzle - - - - - - - - - - - - - - - - - Check Platen Gap - - - - - - - - - - - - - - - Cleaning / Charging (Priming) - - - - - - - - - Clear PF Micro Feed Adjustment [Bi-D] - - - - Copy Bi-D Variables - - - - - - - - - - - - - - Copy Uni-D Variables - - - - - - - - - - - - - CR Encoder Sensor Position Adjustment - - - Head Rank ID - - - - - - - - - - - - - - - - - Initialize Main Board - - - - - - - - - - - - - - Ink Discharge. - - - - - - - - - - - - - - - - - Multi Sensor Adjustment for Auto Nozzle Check Multi Sensor Auto PF Adjustment - - - - - - - Multi Sensor Level Adjustment - - - - - - - - Multi Sensor Position Adjustment - - - - - - - Nozzle Bi-D Adjustment - - - - - - - - - - - - Paper Feed Timing Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - 137 - 138 - 139 - 140 - 141 - 143 - 144 - 145 - 146 - 147 - 148 - 149 - 150 - 151 - 152 - 153 - 154 - 155 - 156 - 158 - 159 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136 Printer Component, Software Item, LCD Display, Printer Button Page 2. Stylus Pro 4000 Field Repair Guide Reference 4/28/05 Paper Thickness Sensor Adjustment Platen Gap Adjustment - - - - - - - Platen Position Adjustment - - - - - Print Head Slant Adjustment (CR) - - Print Head Slant Adjustment (PF) - - RearAD Sensor Calibration - - - - - Reset ASF Counter - - - - - - - - - Reset Paper Ejection Switching - - - Reset PF Motor Counter - - - - - - - Reset When Cleaning Unit Change - Reset When CR Unit Change - - - - Reset When Cutter Change - - - - - Reset When Print Head Change - - - RTC & USB & IEEE1394ID Adjustment Skew Check - - - - - - - - - - - - - T&B&S [Cut Sheet] Adjustment - - - T&B&S [Roll Paper] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 161 - 164 - 167 - 169 - 172 - 175 - 176 - 177 - 178 - 179 - 180 - 181 - 182 - 183 - 187 - 188 - 189 Accessories List - - - - - - - - - - - Cleaning Fluid - - - - - - - - - - - - Color Order on the Print Head - - - - Consumable/Service Parts List - - - Firmware History - - - - - - - - - - Firmware Update Procedure - - - - - Glossary - - - - - - - - - - - - - - - Ink Draining Procedure - - - - - - - Ink Tube Order - - - - - - - - - - - - Prime, On or Off - - - - - - - - - - - Revision History - - - - - - - - - - - Sensors, Motors, Solenoids, and Fans Service Procedure - - - - - - - - - - Service Tools - - - - - - - - - - - - Stress Test (Test Image) - - - - - - - User Nozzle Check Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - 191 - 192 - 193 - 194 - 196 - 201 - 202 - 208 - 209 - 210 - 211 - 212 - 214 - 216 - 217 - 218 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190 Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219 Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220 Printer Component, Software Item, LCD Display, Printer Button Page 3. Stylus Pro 4000 Field Repair Guide 4/28/05 Epson Paper Feed Adjuster - - - - - - - - - - - - - - - - - - - - - - - - - - - 223 NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226 PRNprint.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229 Printer Component, Software Item, LCD Display, Printer Button Page 4. Stylus Pro 4000 Field Repair Guide 4/28/05 Control Panel Map Sheet Roll Auto Cut Roll Auto Cut Off Roll / Sheet Status Media Feed Ink Quantity Maintenance Tank Level Paper Out Ink Out Paused Pause Power Hold for 3 seconds to reset/clear Printer Hold for 3 seconds to cut roll media Hold for 3 seconds to clean Hold the 4 Arrow Buttons and Power on for F/W Download Mode. Printer Component, Software Item, LCD Display, Printer Button Page 5. Stylus Pro 4000 Field Repair Guide 4/28/05 User Menu: Press the Menu button when the printer displays Ready 1. PRINTER SETUP. 3. PRINTER STATUS. VERSION: (CURRENT FIRMWARE) PRINTABLE PG: (FOR EACH COLOR)MK (nnnnnn)PG INK LEFT: (FOR EACH COLOR)MK E*****F MAINT TANK: E*****F USAGE COUNT: INK (nnnn.n)ML, PPR (nnnn.n)CM USE COUNT CLR: EXEC JOB HISTORY: N0.(N) I:(nnn)ML, P:(nnn)CM JOB HISTORY CLR: EXEC TOTAL PRINTS: (nnnn) PLATEN GAP: *STANDARD, NARROW, WIDER, WIDE PAGE LINE: *ON, OFF INTERFACE: *AUTO, USB, IEEE1394, OPTION CODE PAGE: *PC437, PC850, PAPER MARGIN: *T/B 15MM, 15MM, 3MM PPR SIZE CHK: *ON, OFF PPR ALIGN CHK: *ON, OFF TIME OUT: *OFF, 30SEC, 60SEC, 180SEC, 300SEC CUTTER ADJ: EXEC REFRESH MRGN: *ON, OFF SHEET SIZE CHK: *ON, OFF 4. CUSTOM PAPER. AUTO NZL CK: *ON, OFF AUTO CLEANING: *ON, OFF PAPER NUMBER: *STANDARD, NO. (1-10) QUIET CUT: *OFF, ON Platen Gap: Standard, Narrow, Wide, Wider INIT SETTINGS: EXEC Thickness Pat: Print Cut Method: *Standard, Thick (Fast, Slow), Thin Paper PPR Feed Adj: (n.nn)% 2. TEST PRINT. Eject Roller: *Auto, Sheet, Roll Curled, Roll Normal NOZZLE CHECK: PRINT Drying Time: (n.n)sec STATUS CHECK: PRINT Suction: *Standard, -4, -3, -2, -1 JOB INFO: PRINT M/W ADJ: *Standard,1 , 2 CUSTOM PAPER: PRINT Printer Component, Software Item, LCD Display, Printer Button Page 6. Stylus Pro 4000 Field Repair Guide 4/28/05 5. MAINTENANCE 6. Head Alignment. CUTTER REPL: EXEC CHNG INK SET: EXEC (For Changing between 8 and 4 color) PWR CLEANING: N CLEANING Y CLOCK SETTING: (mm/dd/yy hh:mm) PAPER THKNS: *STD, (n.n)MM ALIGNMENT: AUTO, MANUAL Maintenance Mode 1: Press and hold the Pause button and turn on the Printers HEX DUMP: PRINT EXEC (In this mode, the printer prints hexadecimal values received) LANGUAGE: *ENGLISH, PORTUGUE, SPANISH, GERMAN, ITALIAN, FRENCH (Sets the control panel language) UNIT: *METER, FEET/INCH (Set’s the unit of measure that the printer displays) 4CMW72: *OFF, ON (?) CUT PRESSURE: *100% (0%-150%) (Adjusts the Paper Cutter pressure) SSCL: EXEC (Super Strong Cleaning) DEFAULT PANEL: EXEC (Returns Maintenance Mode 1 settings to Factory Default) CRTG INFO MENU: MANUFACTURER,COLOR, INK TYPE, INK CAPACITY, INK LEFT, PRODUCTION DATE, EXPIRATION DATE, INK LIFE, INK AGE (CSIC information, for each ink cartridge) Maintenance Mode 2: Press and hold the Left, Down, and Up buttons and turn on the Printer SELF TESTING: Test: Version: (Displays the current firmware version) Panel: (Button tests for the control panel) Sensor: (Sensor tests for all sensors) Encoder: (Encoder tests for both encoders) Fan: (Fan tests for all fans) Printer Component, Software Item, LCD Display, Printer Button Page 7. Stylus Pro 4000 Field Repair Guide 4/28/05 Elec.: Record: Maintenance: (Usage Counters for the following devices) WasteInk, Wiper, Rubbing, Lever, Cover, Ink Lever, Cr Motor, PF Motor, PrintNumber, Cleaning, Fire A, Fire B, Fire C, Fire D, Fire E, Fire F, Fire G, Fire H, Cut, Cute Sole, LockSolen Record: Error: Error (0 - 6) (Displays the last 7 errors) D/A Revision: Measure Va: (nn.nnn)v (?) CSIC: Slot (1 - 8), Maintenance Tank (?) Actuator: Cutter: [Enter], Start (Tests the cutter assembly) Actuator2: Cutter Sol, Pump Motor (Tests the following devices) Adjustment: Cut Adj.: Pressure: *73% (Adjusts voltage used for the cutter solenoid) PG ADJ: [Enter], Start: PG Offset *(nn) (Used for adjusting the platen gap) Rear AD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the rear paper sensor) Edge Sns Lvl: [Enter], Start: (For adjusting the sensitivity of the edge sensor) Check Nozzle: [Enter] Print: (Service level nozzle check) Check Skew: Check Skew: (n.n)mm (Default 1.0) (Used for setting the amount of allowable skew) Clean Head: (Used for draining the ink system) Counter Clear: Reset Counter? (Resets all counters, DO NOT USE) Ink Drain: (Used for draining the ink system) Cleaning: Std. KK0 (Weakest cleaning cycle (uses less ink)) Std. KK1 (Medium strength cleaning cycle) Std. KK2 (Strongest cleaning cycle) Init. Fill (Forces a initial fill (prime)) Print: Check Ptn.: [Enter] Print (Prints all alignment patterns) Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set) Parameter: Initialize: All: Initialize OK? (Resets all of the following counters at once) Printer Component, Software Item, LCD Display, Printer Button Page 8. Stylus Pro 4000 Field Repair Guide 4/28/05 PF Resolution: Initialize OK? (Resets this counter only) Head Record: Initialize OK? (Resets this counter only) Wiping Record: Initialize OK? (Resets this counter only) Rab. Record: Initialize OK? (Resets this counter only) Waste Record: Initialize OK? (Resets this counter only) CRmot Record: Initialize OK? (Resets this counter only) PFmot Record: Initialize OK? (Resets this counter only) Lever Record: Initialize OK? (Resets this counter only) Cover Record: Initialize OK? (Resets this counter only) Ink Lever Record: Initialize OK? (Resets this counter only) Update: InkParameter: Init. Fill: (Set, Reset) (Reset, turns off the initial fill) MntTank: (On, Off) (Turn on or off the Maintenance Tank CSIC) Mask Type: Dispersion, Regular (?) PF BiD Adjust: (+/- n) (?) Uni-D Trap: (On, Off) (?) Display: Address: (Used for displaying data at specific RAM addresses) Life: CR Motor, PF Motor, CR+PF Motor, Roller, Roller Rel, D/E Chg, Hopper, ASFLoad, Cutter, Head U/D, Head Lock, Cleaning, Print, Total Life, CR+PF+Fire, TotalLife2, TotalLife3, Check (Used for design testing of these devices and assemblies) Service Config Chg DEVICE-ID: *Sty Pro 4000, PX-6000 (Used for choosing the Plug and Play printer name) NPD: *1, 0, 2 (Defines the ink type (1= pigment, 0 = new/undefined, 2 = dye)) EDMODE: *X, O,N (X=CSIC used fully, N=Non-USA Cartridges are OK, O=CSIC is disabled) MD TBL: ID = (1-7D Hex) (“Modifying parameter of media table is available”) View Counters (Displays the usage/life counter information for the following devices/operations) Cutter, Cutter Total, Total Pages, Maint Tank, CR Motor, CR Total, PF Motor, Nozzle A, Nozzle B, Nozzle C, Nozzle D, Nozzle E, Nozzle F, Nozzle G, FL Box, Cleaner, Sponge, ASF, Feed Roller, PG Printer Component, Software Item, LCD Display, Printer Button Page 9. Stylus Pro 4000 Field Repair Guide 4/28/05 Clear Counters (Clears the usage/life counter information for the following devices/operations) Init All: (Initializes all the following counters at once) NVRAM, RTC: (YY/MM/DD/HH), Cutter, CR Motor, CR Total, PF Motor, Head, Cleaner, Total Pages, MAINT TANK, SPONGE, ASF,FEED ROLLER, PG, CR UNIT MAINT, CL UNIT MAINT, HEAD MAINT, CUT UNIT MAINT (Sponge = Boarderless Pads) MAINT INFO: (Page 88 - 98 in the Service Manual) Menu E: (E1 - E17), Menu R: (R1 - R9), Menu S: (S1 - S25), Menu A: (A1 - A32), Menu B: (B1 - B48), Menu P: (P1 - P42), Menu M: (M1 - M26), Menu O: (O1 - O28), Menu F: (F1 - F28), Menu N: (N1 - N22) INIT INFO (Resets MAINT INFO menu data) INIT. MENU E:, INIT. MENU R:, INIT. MENU S:, INIT. MENU A:, INIT. MENU B:, INIT. MENU P:, INIT. MENU M:, INIT. MENU O:, INIT. MENU F:, INIT. MENU N: Maintenance Mode 3: Press and hold the Pause, Down, and Right buttons and turn on the Printer Shipment: ADJ.Variable: Exec (Prints out the current adjustment settings) Clean Head: Exec (Evacuates the ink in the Ink Tubes) Clean Counter: Exec (Resets counters?) Default Panel: Exec (Resets the Control Panel Settings to factory default) Parameter Backup Mode: (Allows Parameter backup without the Printer being online) 1. Enter Maintenance Mode 2: Press and hold the Left, Down, and Up buttons and turn on the Printer 2. Lift both (2) Ink Levers 3. Remove the Maintenance Tank 4. Move the Paper Release Lever to the released position. Firmware Download Mode: Hold the 4 Arrow Buttons and Power on for F/W Download Mode Printer Component, Software Item, LCD Display, Printer Button Page 10. Stylus Pro 4000 Field Repair Guide 4/28/05 Printer Component, Software Item, LCD Display, Printer Button Page 11. Stylus Pro 4000 Field Repair Guide 4/28/05 Component Replacement Printer Component, Software Item, LCD Display, Printer Button Page 12. Stylus Pro 4000 Field Repair Guide 4/28/05 Carriage Removal Procedure 1. Unplug the Printer. 2. Raise both Ink Levers, closing the Ink Valves. 3. Remove the Left Side Cover. 4. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position. 5. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt. Mark Belt Tension Gauge Carriage Removal Procedure Loosen Belt tension Printer Component, Software Item, LCD Display, Printer Button Remove Belt from the Carriage Motor Page 13. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown. 1.75” wide .5” wide, and1/4” deep V slot 5” long 2. Place the jig so that the V slots support the Carriage Rail Covers Note:The jig should be placed so that it supports the Carriage Rail Covers beside to the Print Head, when it is in the removal position (see step 8). Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 14. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing Strip Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 15. Stylus Pro 4000 Field Repair Guide 4/28/05 Cartridge Release Lever Repair 1. Remove the Ink Bay. 2. Ensure that the Gears and Spring are in the positions shown. (This is the Cartridge released, and the Valves closed position) Ensure that the Valve Open/Close Cam is fully seated in the Interlocks. Cartridge Release Lever Repair Spring position Printer Component, Software Item, LCD Display, Printer Button 3 Gear positions to check. Page 16. Stylus Pro 4000 Field Repair Guide 4/28/05 Cartridge Release Sensor Repair 1. Remove the Ink Bay Assembly. 2. Remove the Cartridge Release Sensor, and replace. The Sensor is fastened by 2 Interlocks. Cartridge Release Sensor Repair Printer Component, Software Item, LCD Display, Printer Button Page 17. Stylus Pro 4000 Field Repair Guide 4/28/05 Damper Removal 1. Raise both Ink Levers, closing the Ink Valves. 2. Remove the Left Side Cover. 3. Move the Carriage Mechanism to the left as shown, remove 3 Screws, and remove the Carriage Cover. Slot 3 Screws Lift off Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 18. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Disconnect 4 Cables, remove 1 Screw, and remove the Junction Board 1. Disconnect 4 Cables. 2. Remove 1 Screw. 3. Remove the Junction Board. 5. Remove 4 Screws, 1 Stay Bar, and 1 Spring. 1 Stay Bar 1 Spring 4 Screws Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 19. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Disconnect the Ink Lines, from the Dampers to be replaced. Disconnect the Lines at the Damper (bottom of the Elbow Joint). Move the Lines to the side, and fasten out of the way. 7. Remove the Stay Bar that fastens the Dampers to the Assembly. Remove the Stay Bar. Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 20. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Lift out the Print Head / Damper Assembly. 9. .Turn over the Print Head / Damper Assembly and remove 3 Screws. Remove 3 Screws. Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 21. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Disconnect the Print Head from the Damper Assembly. 1. Disconnect the Print Head from the Damper Assembly. 2. Hold the Damper Assembly like this so that ink does not leak. 3. Place the Print Head off to the side as shown. 11. Release the Interlock that corresponds to the Damper(s) to be replaced, and lift out the Damper(s) Damper Interlock Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 22. Stylus Pro 4000 Field Repair Guide 4/28/05 12. Install the new Damper(s). 13. Re-connect the Ink Tubes to the new Dampers, and manually prime all the Dampers. With the Damper openings facing up, draw the air out of the each Damper. 14. Reconnect the Print Head to the Damper Assembly. Connect the Print Head and fasten with 3 Screws. Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 23. Stylus Pro 4000 Field Repair Guide 4/28/05 15. Place the Print Head / Damper Assembly back into the Carriage Mechanism. 16. Replace 4 Screws, 1 Stay Bar, and 1 Spring. 1 Stay Bar 1 Spring 4 Screws Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 24. Stylus Pro 4000 Field Repair Guide 4/28/05 17. Re-install the Junction Board, fasten with 1 Screw, and reconnect 4 Cables. This Connector has a latch. Install the Junction Board and fasten with 1 Screw. Reconnect 4 Cables. 18. Perform cleaning cycles and nozzle checks until the nozzles are working. 19. Perform the Print Head mechanical adjustments. 19.1 Perform the Print Head Slant Adjustment (CR) 19.2 Perform the Print Head Slant Adjustment (PF) Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 25. Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Bay Removal (Left) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. Remove 4 Screws Remove 5 Screws (View from the back) Remove 1 Screw 3. Remove 2 Screws fastening the Front Panel. Remove 2 Screws Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 26. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 1 Screw Remove 4 Screws Ink Bay Removal (Left) This hole in the Cover allows easy access to the Cartridge Release Handle Screw Printer Component, Software Item, LCD Display, Printer Button Lift off the Cover. Page 27. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 2 Screws and 2 Brackets 1 Screw and Bracket on the Right Side 1 Screw and Bracket on the Left Side 7. Remove 2 Screws from the front. 2 Screws from the front Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 28. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Remove 2 Screws from the back of the Ink Bay Assembly. Blow up of this area Look through this area, on the back of the Printer, to find 2 Screws Remove 2 Screws 9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable. Cartridge Release Sensor Cable 4 CSIC Cables Re-assembly Note: Cable Order Yellow-Magenta-Cyan-Matte Black Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 29. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Maneuver the Ink Tubes from the Slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 30. Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Bay Removal (Right) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. Remove 4 Screws Remove 5 Screws (View from the back) Remove 1 Screw 3. Remove 2 Screws fastening the Front Panel. Remove 2 Screws Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 31. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 4 Screws Ink Bay Removal (Right) Remove 1 Screw Printer Component, Software Item, LCD Display, Printer Button Lift off the Cover. Page 32. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 4 Screws and 2 Brackets 1 Screw and Bracket on the right side 1 Screw and Bracket on the left side 1 Screw on the left Side 1 Screw on the right Side. 7. Remove 2 Screws from the front. 2 Screws from the front Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 33. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Remove 2 Screws from the back of the Ink Bay Assembly. View is from the back of the Printer Pump Assembly Remove 2 Screws 9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable. Cartridge Release Sensor Cable 4 CSIC Cables Re-assembly Note: Cable Order Top to Bottom Black, Light Cyan, Light Magenta, Light Black Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 34. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Maneuver the Ink Tubes from the slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 35. Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly, Disassembly 1. Remove the E-Ring, Gear, and Paddle shown below. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 36. Stylus Pro 4000 Field Repair Guide 4/28/05 2. Detach the 3 Interlocks that fasten the Input Roller Cover, and slide the Cover off the Roller. Detach 3 Interlocks Slide off the Cover 3. Remove the 2 E-Rings shown below Remove the E-Ring Input Roller Assembly, Disassembly Remove the E-Ring Printer Component, Software Item, LCD Display, Printer Button Page 37. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Detach the 3 Interlocks holding the remaining Roller Cover, and slide it off. 3 Interlocks 5. Slide the remaining components off the Shaft. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 38. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Release the Interlocks, as shown below. 7. Lift up the Paper Tray Base, and remove the Separation Pad Assembly as shown below. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 39. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Maneuver the remaining side of the Paper Tray Base as shown below to free the last Separation Pad Assembly. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 40. Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly, Re-assembly 1. Assemble the Base Unit until it looks this. 2. Maneuver the Separation Pad Assembly into the slot as shown. Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 41. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Re-hook the Interlock / Pivot Points that connect the Separation Pad Assembly to the Base. 4. Press down on the Separation Pad Assembly until the Black Levers lock it in the down position. These two pieces must be pressed tightly together to allow the Paper Separation Assembly too fully compress the Springs. Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 42. Stylus Pro 4000 Field Repair Guide 4/28/05 5. Study the polarity, and order of the parts below. Paddles positioned, so that the arrow on the side faces up The Disks have depressions, that fit the Springs. Home Position Window faces the opposite direction from the flat side of the Roller. The Right and Left Rollers are different. Pay attention to the position of the Slots. 6. Install the Roller Assembly components into the Base Assembly, following the directions above. Paddle on the outside of the Frame. Paddle on the inside of the Frame. Cover marked with R Input Roller Assembly, Re-assembly Cover marked with L Printer Component, Software Item, LCD Display, Printer Button Page 43. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Rotate the Input Rollers so that the flat side is down to allow the Roller to interlock with the Roller Frame. Flat side down This part of both Rollers must fit through the Roller Side Frame. 8. Re-attach the Roller Covers, 3 E-rings, and Gear. 1 E-Ring between the Roller Assembly and the Frame. 1 E-Ring fastening this Gear. Gear Input Roller Assembly, Re-assembly 2 Roller Covers Printer Component, Software Item, LCD Display, Printer Button E-Ring Page 44. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Test the Roller Assembly before installation Place a piece of paper in the Tray. Input Roller Assembly, Re-assembly Rotate the Gear and check for proper operation Printer Component, Software Item, LCD Display, Printer Button Page 45. Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly Removal 1. Remove the Left Side Cover. 2. Remove the Right Side Cover. 3. Remove the Ink Cartridges, and leave the Levers up (closing the Valves). Lever up, closing the Valves Lever up, closing the Valves 4. Remove the Rear Paper Guide Support and the Paper Jam Cover. Rear Paper Guide Support (directions at step 5) Remove the Paper Jam Cover (shown removed) Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 46. Stylus Pro 4000 Field Repair Guide 4/28/05 5. 1. Remove this Screw on the left. 2. Remove this Screw on the right. 3. Free the Rear Paper Guide Support from the Printer. 4. Remove the Screw that holds the Manual Feed Sensor to the Support. 5. Remove the Sensor from the Rear Paper Guide Support Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 47. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Rotate the Printer onto it’s back. 7. Remove the 2 screws fastening the Right Side Air Duct to the Frame. 2 Screws Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 48. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Lift the Right Side Air Duct exposing the 2 Screws noted in step 9. This is 1 of the 2 Screws shown is the picture on the left in step 9. 9. Remove the 3 Screws that fasten the Input Roller Assembly to the Right Side Frame. Back side of the Waste Ink Tank Slot 3 Screws Loosen this Screw. Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 49. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Remove the 3 Screws that fasten the Input Roller Assembly to the Left Side Frame. 3 Screws 11. Slide the Input Roller Assembly out about 2 inches, disconnect the Input Roller HP Sensor, and fully remove the Assembly. Left side of the Printer Input Roller Home Position Sensor Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 50. Stylus Pro 4000 Field Repair Guide 4/28/05 Main Board Replacement 1. Back up the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe) 2. Turn off the Printer and UNPLUG from AC. 3. Remove the Rear Paper Guide Assembly. Push the 2 Grey Tabs and pull out the Cover 4. Remove the 6 Screws fastening the Main Board Housing. 3 Screws Main Board Replacement 3 Screws Printer Component, Software Item, LCD Display, Printer Button Page 51. Stylus Pro 4000 Field Repair Guide 4/28/05 5. Slide out the Main Board Housing until the Cable Connectors are visable. 6. Un-fasten the Cables Pull up on the Connector Releases, to release these 3 Cables The number on the Foil Cable corresponds to the Connector number Pull up on the Connector Release, to release this Cable Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 52. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Remove the 5 Screws and Hardware fastening the Ports to the Main Board Housing. 5 Screws Removing the Firewire Hardware is necessary for re-assembly. 8. Remove the 9 Screws fastening the Board to the Housing. 5 Screws 4 Screws Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 53. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Fasten the new Board to the Housing with 9 Screws (see above) Do not fully tighten. 10. Install the Port Covers and 5 Screws 5 Screws 11. Full tighten the 9 Main Board Screws. 12. Connect the Cables to the Board. Ensure that the Cables are fully seated (straight). Lift the Release Mechanisms on these 4 Connectors Hold the Cable firmly in place, while locking the Release Mechanism. Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 54. Stylus Pro 4000 Field Repair Guide 4/28/05 13. Write down the IEEE (Firewire) ID, if the Printer’s Parameters are not available. The IEEE ID is located in the Main Board Cavity 14. Attach the Board Housing to the Printer and fasten with 6 Screws. Tilt the Board Assembly, while inserting, so that the leading edge drops on to the Printer Mechanism’s Board Support Ledge. Main Board Replacement Fasten with 6 Screws Printer Component, Software Item, LCD Display, Printer Button Page 55. Stylus Pro 4000 Field Repair Guide 4/28/05 15. Down load the current firmware version. 15.1 Open the PRNPRINT application, and prepare to send the current firmware version to the Printer. 15.2 Turn on the Printer while depressing the Left, Up, Down, and Right arrow buttons, The Printer will display UPDATE F/W. 15.3 Send the current firmware to the Printer. 16. Re-Install the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe) 16.1 Perform the RTC&USBID&IEEE1394ID Adjustment. If the Printer’s Parameters are not available skip step 16, and follow step 17. 17. Perform the following operations in the order listed. 17.1 Stop the Printer from priming (See The Prime ON / Off chapter). 17.1.1 Note: Init.Fill: Reset = The Printer ‘s prime function is turned off. 17.2 Perform the Rear Sensor AD Adjustment. 17.3 Perform the Cutter Pressure adjustment. 17.4 Perform the Platen Gap adjustment. 17.5 Enter the Head Rank ID (Print Head calibration values). 17.6 Perform the Multi Sensor Level Adjustment. 17.7 Perform the Print Head Slant (CR) Adjustment. 17.8 Perform the Print Head Slant (PF) Adjustment. 17.9 Perform the Multi Sensor Adjustment for Auto Nozzle Check. 17.10Perform the Nozzle Bi-D Adjustment. 17.11Perform the Auto Bi-D Adjustment. 17.11.1Copy Bi-D variables 17.12Perform the Auto Uni-D Adjustment. Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 56. Stylus Pro 4000 Field Repair Guide 4/28/05 17.12.1Copy Uni-D variables. 17.13Perform the Platen Position Adjustment 17.14Perform the Clear Micro Feed PF Adjustment (Bi-D) 17.15Perform the 1000 mm Feed Adjustment, or Multi Sensor Auto PF Adjustment. 17.16Perform the T&B&S (Roll Paper) Adjustment. 17.17Perform the T&B&S (Cut Sheet) Adjustment. 17.18Perform the RTC&USBID&IEEE1394ID Adjustment. Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 57. Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Exit Roller Removal 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. Remove 4 Screws Remove 5 Screws (View from the back) Remove 1 Screw 3. Remove 2 Screws fastening the Front Panel. Remove 2 Screws Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 58. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove the2 Screws that fasten the Exit Roller. Remove 2 Screws Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 59. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove the Exit Roller. 7. The Exit Roller must be re-installed using the correct polarity.j Long end Gold Spring side, on the top Silver Spring side, on the bottom Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Short end Page 60. Stylus Pro 4000 Field Repair Guide 4/28/05 Plastic Roller Upgrade Note: This procedure documents the replacement of 9 Plastic Rollers with 9 Rubber Coated Plastic Rollers. These Rollers make contact with the printable side of the media. The old Roller design could scuff the surface of Fine Art Media. 1. Remove the Left Side Cover. 2. Remove the Right Side Cover. 3. Remove the Paper Release Lever Assembly Cover. 1. Remove 1 Screw. 2. Remove the Cover. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 61. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Top Cover as shown. Lever up both sides of the Top Cover at the Hinges. 5. Remove the Top Cover Component shown below. Remove 1 Screw Remove 1 Screw Lift of the Top Cover Component. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 62. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove the Paper Thickness Sensor Assembly. Remove these 2 Screws. Remove the 2 Screws accessed through these holes. Lift off the Paper Thickness Sensor Assembly. Do not loosen these 2 Screws. 7. Remove the Rear Paper Guide Support and the Paper Jam Cover. Rear Paper Guide Support (directions at step 8) Remove the Paper Jam Cover (shown removed) Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 63. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Paper Guide Support removal 1. Remove this Screw on the left. 2. Remove this Screw on the right. 3. Free the Rear Paper Guide Support from the Printer. 4. Remove the Screw that holds the Manual Feed Sensor to the Support. 5. Remove the Sensor from the Rear Paper Guide Support Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 64. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Remove the Paper Release Lever Assembly. Remove 2 Screws. Remove the Assembly. 10. Remove the Paper Release Transmission Gear. 1. Note the position of the Gear in relation to this Rubber Stopper. 2. Remove the Gear. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 65. Stylus Pro 4000 Field Repair Guide 4/28/05 11. Remove the Gear shown below. To remove this Gear, follow the 4 steps listed below. 1. Note the Gears’ orientation to this Rubber Stopper. 2. Note the Interlock on the back side of the Gear. Plastic Roller Upgrade 3. Rotate the Gear so that the Interlock is in this position. Printer Component, Software Item, LCD Display, Printer Button 4. Remove the Gear. Page 66. Stylus Pro 4000 Field Repair Guide 4/28/05 12. Remove the Roller Assembly. Remove the Roller Assembly by finessing the right side of the Assembly out, followed by the left. 13. Place the Roller Assembly on a flat surface. Ensure that the Assembly is in this position Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 67. Stylus Pro 4000 Field Repair Guide 4/28/05 14. Remove 4 Screws that fasten the Release Roller to the Assembly, and remove the Roller. 15. Flip up the white Paper Guides so that the Assembly is in this position.l Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 68. Stylus Pro 4000 Field Repair Guide 4/28/05 16. Inspect 1 of the 3 Paper Guides and note the items listed below. The Shaft ends here, and goes next to this Support. Note the way that the Shaft is behind some Supports, and under others. The Shaft ends here, and goes next to this Support. The Hook on the Springs goes to the right. These are the Rollers to be replaced. 17. Remove the 3 Paper Guide Assemblies, and install the new Rollers. Old Rollers Plastic Roller Upgrade New Rollers. Printer Component, Software Item, LCD Display, Printer Button Page 69. Stylus Pro 4000 Field Repair Guide 4/28/05 18. Lay out the Assembly Components like this. 19. Attach the Guides to the Frame starting on the right. 1. Under here. 4. Under here. 2. Over here. 5. Over here. 3. Spring in the Notch. 6. Spring in the Notch. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 70. Stylus Pro 4000 Field Repair Guide 4/28/05 20. It should look like this when installed correctly. 21. Use the same method to replace the second and third Guide Assemblies. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 71. Stylus Pro 4000 Field Repair Guide 4/28/05 22. The Assembly should look like this when the 3 Guides are installed. 23. Lay out the remaining Components like this. Square opening on this end. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 72. Stylus Pro 4000 Field Repair Guide 4/28/05 24. Note these aspects of the Release Roller. Square Hole on the left side. These Notches make contact with the White Guides. 25. Place the Release Roller against the White Guides.j Square Hole on this side. Plastic Roller Upgrade Notches against the White Guides. Printer Component, Software Item, LCD Display, Printer Button Page 73. Stylus Pro 4000 Field Repair Guide 4/28/05 26. Fasten the Release Roller with 1 Bracket in the middle, and then install the remaining Brackets. 27. Spin the Release Roller and verify that the Guides and Notches line up properly. Guides and Notches should look like this. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 74. Stylus Pro 4000 Field Repair Guide 4/28/05 28. Install the Roller Assembly. 1. Insert the Left Side first. Plastic Roller Upgrade 3. Install 2 Screws. 2. Insert the Right Side second. Printer Component, Software Item, LCD Display, Printer Button Page 75. Stylus Pro 4000 Field Repair Guide 4/28/05 29. Install the Paper Thickness Sensor Assembly. Fasten with 2 Screws. 30. Install the Gear pictured below. Insert this Gear. It is “keyed’ and will only insert 1 way. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 76. Stylus Pro 4000 Field Repair Guide 4/28/05 31. Attach the Release Transmission Gear and the Release Lever Assembly. 2. Install this Assembly so that the Gear is held in place. 1. Insert this Gear. 3. Fasten with 2 Screws. 32. Attach the Manual Feed Sensor to the Paper Guide. 1. Hold in place on the back side of the Guide. 2. Route the Wire through the Fasteners. 3. Fasten with 1 Screw. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 77. Stylus Pro 4000 Field Repair Guide 4/28/05 33. Install the Paper Guide Assembly and fasten with 2 Screws. 1 Screw 1 Screw 34. Perform the Paper Thickness Sensor Adjustment. 35. Install the Plastic Cover pictured below, and fasten with 3 Screws. 1 Small Head Screw. 2 Big Head Screws. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 78. Stylus Pro 4000 Field Repair Guide 4/28/05 36. Install the Top Cover. Lever the Pivot into the Hinges. 37. Install the Paper Release Lever Assembly Cover. 1. Install the Cover. 2. Fasten with 1 Screw. 38. Replace the Left and Right Side Covers. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 79. Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Replacement Procedure 1. Run the Adjustment Wizard and input the new Print Head’s calibration value. 2. Unplug the Printer. 3. Raise both Ink Levers, closing the Ink Valves. 4. Remove the Left Side Cover. 5. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position. 6. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt. Mark Belt Tension Gauge Print Head Replacement Procedure Loosen Belt Tension Printer Component, Software Item, LCD Display, Printer Button Remove Belt from the Carriage Motor Page 80. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown. 1.75” wide .5” wide, and1/4” deep V slot 5” long 2. Place the jig so that the V slots support the Carriage Rail Covers Note:The jig should be placed so that it supports the Carriage Rail Covers beside to the Print Head, when it is in the removal position (see step 8). Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 81. Stylus Pro 4000 Field Repair Guide 4/28/05 8. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing Strip 9. Turn over the Carriage Mechanism, and support it with one hand (ensure that the Nozzles and the Carriage Encoder are not damaged). Remove 3 Screws Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 82. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Remove the Print Head by rotating the top of the Head away from the Carriage. 11. Remove 3 Screws fastening the Head to the Head Case. Remove 3 Screws Separate the Print Head from the Print Head Case. Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 83. Stylus Pro 4000 Field Repair Guide 4/28/05 12. Disconnect the Print Head Cables Gently remove the Cables. The Top Cable is the 0 Cable. 13. Connect the new Print Head to the Cables. Ensure that the 0 Cable is on top (Nozzle Plate side). 14. Attach the Print Head to the Head Case. 15. Attach the Head Case to the Carriage Mechanism. 16. Re-install the Carriage Mechanism. 16.1 Ensure that the Timing Strip is routed through the Sensor. 16.2 Use the Carriage Rail Cover protection jig. 17. Place the Carriage Belt on the Carriage Motor Pulley. 18. Tighten the Carriage Belt until the Gauge reaches the mark that represents the proper tension. Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 84. Stylus Pro 4000 Field Repair Guide 4/28/05 19. Verify that the Carriage Rail Covers, Carriage Bearings, Carriage Belt and Timing Strip are properly in place. 20. Move the Carriage Mechanism to the capped position. 21. Plug in the Printer, and lower both Ink Cartridge Levers to open the Ink Valves. 22. Defeat the Cover Sensor, and turn on the Printer. 23. Turn on the Printer, and let it come Ready. 24. Press the Menu button and navigate to Maintenance. 25. Press the Menu button and navigate PWR CLEANING. 26. Press the Menu button to execute. 27. Print a Nozzle Check Pattern (Perform standard cleanings if necessary). 28. Perform the following adjustments in sequence. Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 85. Stylus Pro 4000 Field Repair Guide 4/28/05 28.1 Perform Reset When Print Head Change 28.2 Perform the Print Head Slant Adjustment (CR) 28.3 Perform the Print Head Slant Adjustment (PF) 28.4 Reset (initialize) the user settings using the Epson Paper Feed Adjuster utility. 28.5 Perform the Nozzle Bi-D Adjustment 28.6 Perform the Auto Bi-D Adjustment 28.7 Perform Copy Bi-D variables 28.8 Perform the Auto Uni-D Adjustment 28.9 Perform Copy Uni-D variables Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 86. Stylus Pro 4000 Field Repair Guide 4/28/05 Pump and Cap Installation 1. Before installing the Pump and Cap Assembly identify the Tube Receptacles where the Pump Tubes must be inserted. Blow up view Tubes go here 2. Before installing the Pump and Cap Assembly, note this detail. The Plastic Tray that sits under the Pump, and that the Tubes are inserted into, has one corner that sits on top of the Pump / Cap Assembly Frame. View from the bottom. Note the Plastic Tray is on top of the Frame Mount. View from the back of the Printer. The Plastic is on top of the Frame. Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 87. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Insert the Cap Assembly part of the way, through the back of the Printer. If the Ink Tubes are not fully inserted, the Ink may bubble back through the cap. Slide the Cap and Pump Feed the Tubes into the receptacle Assembly, part of the way in Assist the Tubes fully into the receptacle, while sliding in the Assembly. 4. Install the 4 Screws securing the Cap and Pump Assembly. Ensure that the Assembly is correctly seated to avoid carriage errors. 2 Screws Ensure that the Flushing Box Screw Hole is correctly aligned before tightening the Assembly screws. 2 Screws Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 88. Stylus Pro 4000 Field Repair Guide 4/28/05 5. Install the Flushing Box and fasten with 1 Screw Tube into the hole leading to the Waste InkTank 1 Screw 6. Plug in the Pump Home Position Sensor. Plug in Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 89. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Install the Gear and Shaft Assembly, and fasten it with 2 Screws. Install Gear and Shaft Assembly. 2 Screws 8. Install the Platen Gap Motor, and fasten with 2 Screws. Install the Motor 2 Screws Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 90. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Install the Trigger Shaft. Insert Trigger Shaft into the Right Side Frame Flex the Trigger Shaft from the back side of the Printer, until the end of the Shaft can be inserted into the Socket Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Insert Into Socket here Page 91. Stylus Pro 4000 Field Repair Guide 4/28/05 10. Replace the Trigger Spring. Spring goes here. Ensure that the Splash Guard is routed as shown. 11. Replace the Trigger Assembly End Piece. Trigger Assembly End Piece here 12. Perform Reset When Cleaning Unit Change (if the Cap/Pump Assembly was changed). Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 92. Stylus Pro 4000 Field Repair Guide 4/28/05 Pump and Cap Removal 1. Remove the Right Side Cover. 2. Remove the Flushing Box. Remove Screw. Lift out the Flushing Box. 3. Remove the Trigger Assembly End Piece and Spring. Trigger Assembly End Piece Trigger Spring Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 93. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Flex the Trigger Shaft until the end farthest from the Side Frame clears it’s Socket, then remove the Shaft. Flex the Shaft from behind Free the end of the Shaft from it’s Socket Slide out the Trigger Shaft 5. Remove 4 Screws securing the Cap and Pump Assembly. 2 Screws 2 Screws Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 94. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 2 Screws fastening the Platen Gap Motor, and remove. 2 Screws Remove the Motor 7. Remove 2 Screws fastening the Gear and Shaft Assembly, and remove. Remove Gear and Shaft Assembly. 2 Screws 8. Slide the Cap and Pump Assembly to the right, to separate the Assembly from the Gear. Separate the Assembly from the Gear Pump and Cap Removal Slide the Cap and Pump Assembly this way. Printer Component, Software Item, LCD Display, Printer Button Page 95. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Unplug the Pump Home Position Sensor. Re-assembly note: The Plastic Tray that the Pump / Cap Assembly covers, sits on top of the Pump / Cap Assembly Frame at this corner. Unplug 10. Slide the Cap and Pump Assembly out the back of the Printer. Remove from the back of the Printer Slide the Assembly to the back Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 96. Stylus Pro 4000 Field Repair Guide 4/28/05 Cap and Pump Assembly Components. Cap Wiper Blade Pump Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 97. Stylus Pro 4000 Field Repair Guide 4/28/05 Side Cover Removal (Left) Remove Screw Remove Screw The Left Side Cover will slide off Remove 2 Screws Side Cover Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 98. Stylus Pro 4000 Field Repair Guide 4/28/05 Side Cover Removal (Right) Remove the Rear Paper Guide Assembly Remove Screw Side Cover Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 99. Stylus Pro 4000 Field Repair Guide 4/28/05 Remove Waste Ink Tank Remove Screw Remove 2 Screws and slide off Lever Remove 2 Screws The Right Side Cover will slide off. Side Cover Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 100. Stylus Pro 4000 Field Repair Guide 4/28/05 Top Cover Removal 1. Using a small flat head screw driver, lever the right Top Cover Hinge pivot point out of the Hinge Frame. 2. Using a small flat head screw driver, lever the left Top Cover Hinge pivot point out of the Hinge Frame. 3. Lift off the Top Cover. Top Cover Removal Printer Component, Software Item, LCD Display, Printer Button Page 101. Stylus Pro 4000 Field Repair Guide 4/28/05 Troubleshooting Printer Component, Software Item, LCD Display, Printer Button Page 102. Stylus Pro 4000 Field Repair Guide 4/28/05 Error Codes (Maintenance) 0002 Carriage Motor / Ink Tube end of life (Clear Carriage Motor Counter) 0004 Nozzle check error 0008 RTC error (Real Time Clock) (Check the Battery and reset the Date and Time) 0010 Multi Sensor Error 0020 Print Head life counter (Reset the Head counter) 0040 Cleaner Unit end of life (Clear the Cleaner counter) 0080 Date is not set (Set the date and time (RTC)) 0100 RTC Battery low (Replace the battery, and reset the RTC) 0200 Paper feed roller life (over 75,000 sheets) (Reset the ASF counter) Error Codes (Maintenance) Printer Component, Software Item, LCD Display, Printer Button Page 103. Stylus Pro 4000 Field Repair Guide 4/28/05 Error Codes (Service) 00000088 RTC (Real Time Clock) data is corrupted 00000101 Carriage Motor life (Reset Carriage Motor Counter, check for leaky ink tubes) 00000103 RTC (Real Time Clock) battery is defective 00000105 Print Head end of life (Inspect print head and reset head counter) 00010000 Paper Feed Motor encoder check error (Check Sensor and Timing Disk) 00010001 Paper Feed Motor out of step 00010002 Paper Feed Motor overcurrent (Check for mechanical binding of the feed rollers / motor) 00010003 Paper Feed Motor in-position time-out 00010004 Carriage Motor encoder check error (Check sensor and Timing Disk) 00010005 Carriage Motor out of step 00010006 Carriage Motor overcurrent (Check for mechanical binding, If not replace motor) 00010007 Carriage Motor in-position time-out 00010008 Servo interrupt watchdog time-out 00010009 System interrupt watchdog time-out 0001000A Carriage home position error (Check Sensor and mechanical components) 0001000C Platen Gap home position error (Check Sensor and mechanical components) 0001000F Carriage Motor PWM output faulty 00010010 Paper Feed Motor PWM output faulty 0001001B Head driver (TG) temperature error 0001001D Carriage servo parameter error Error Codes (Service) Printer Component, Software Item, LCD Display, Printer Button Page 104. Stylus Pro 4000 Field Repair Guide 4/28/05 0001001E Paper feed servo parameter error 00010020 CSIC read / write error 00010022 Ink type error 00010023 RTC (Real TIme Clock) (Reset RTC) 00010025 CSIC ROM communication error 00010026 RTC (Real TIme Clock) communication error 00010028 Head error 00010029 Unidentified NMI 0001002A Carriage ASIC ECU error 0001002B Paper feed ASIC ECU error 0001002D Cleaning Unit end of life 0001002F 360 DPI writing time out error 00010030 Multi Sensor failure (1. Check sensor, 2. calibrate sensor, 3. replace sensor) 00010031 ASF (Auto Sheet Feeder) home position error (Check Sensor and mechanical components) 00010032 ASF (Auto Sheet Feeder) Drive Switch error (Check Sensor and mechanical components) 00010033 Exit Roller home position error (Check Sensor and mechanical components) 00010034 Eject Roller lifted (Customer Safety Sensor on the eject roller) 00010035 Pump Home Position Error (Check Sensor and mechanical components) 00010036 Type B 1394 (Firewire) board installation (Remove Firewire Card / not allowed) 00010037 Print Head thermistor error 00010038 Head Driver thermistor error Error Codes (Service) Printer Component, Software Item, LCD Display, Printer Button Page 105. Stylus Pro 4000 Field Repair Guide 4/28/05 00010039 PG adjustment value NVRAM error 0001003A PG adjustment value NVRAM error 0001003B Carriage Lock / Cutter Error 0001003C Carriage Lock / Cutter Error 0001003D Carriage Lock / Cutter Error 00020000 NVRAM error 00020002 SDRAM error 00020003 BOOT program SUM error 00020009 Flash memory SUM error 0002000A Program load error 0002000B Internal memory shortage error 0002000C Review error 100000E0 CPU address error (load misalignment) 10000100 CPU address error (storage misalignment) 10000180 CPU reserve command code exception error 100001A0 CPU slot illegal command exception error 100001C0 AC disruption (AC Power) (Unplug and wait 30 sec., then plug back in) 100005C0 CPU DMA address error 0003xxxxx 0Dxxxxxxx CPU error Error Codes (Service) Printer Component, Software Item, LCD Display, Printer Button Page 106. Stylus Pro 4000 Field Repair Guide 4/28/05 00000088 Note: The 00000088 error code indicates that the RTC (Real Time Clock) data is incorrect. 1. Set the RTC by accessing the Maintenance Mode 2: Clear Counters: RTC counter. 2. Replace the Main Board, if the RTC data can not be set. 00000088 Printer Component, Software Item, LCD Display, Printer Button Page 107. Stylus Pro 4000 Field Repair Guide 4/28/05 00000101 Note: The 00000101 error code indicates that the Carriage Motor and Ink Tubes have reached their end of life. 1. Inspect the Ink Tubes for leaks or cracks. 2. Inspect the Carriage Motor for wear. 2.1 Spin the Motor manually and feel for friction. 2.2 Replace the Motor if necessary. 3. Clear the Maintenance Mode 2: Clear Counters: CR Motor counter. 00000101 Printer Component, Software Item, LCD Display, Printer Button Page 108. Stylus Pro 4000 Field Repair Guide 4/28/05 00000103 Note: The 00000103 error code indicates that the RTC Battery is defective. 1. Replace the RTC Battery located on the Main Board. 2. Replace the Main Board. 00000103 Printer Component, Software Item, LCD Display, Printer Button Page 109. Stylus Pro 4000 Field Repair Guide 4/28/05 00000105 Note: The 00000105 error code indicates that the Print Head has reached it’s end of life. 1. Inspect the Print Heads operation using the Printer’s Maintenance Mode 2: Self Testing: Adjustment: Check Nozzle function. 1.1 Replace the Print Head if necessary. 2. Clear the Maintenance Mode 2: Clear Counters: Head counter. 00000105 Printer Component, Software Item, LCD Display, Printer Button Page 110. Stylus Pro 4000 Field Repair Guide 4/28/05 00010000 - 00010003 Note: The 00010000 - 00010003 range of error codes indicates that the Paper Feed Motor or Encoder is defective. 1. Manually check the operation (spin) of the Paper Feed Motor. 2. Check the operation of the Paper Feed Encoder using the Maintenance Mode 2: Self Testing: Test: Encoder:PF Encoder menu item. 00010000 - 00010003 Printer Component, Software Item, LCD Display, Printer Button Page 111. Stylus Pro 4000 Field Repair Guide 4/28/05 Color Shift Note: Most color shift issues are not caused by a printer problem, but by the customers “work flow”. “work flow” refers to the customers color management. Usually the printer will accurately print the image that it is sent. If the customer is un-aware of the true color of the image, because of a “work flow” issue, the customer will blame the Printer for the perceived color inaccuracy. Missing Nozzles can impact color, so they should be checked. Use your computer, driver, image, and paper to verify the operation of the Printer. If the color appears normal, then the user’s “work flow” is the issue. If the color is incorrect using your materials, and the customers, a new Main Board may correct the issue. Color Shift Printer Component, Software Item, LCD Display, Printer Button Page 112. Stylus Pro 4000 Field Repair Guide 4/28/05 Command Error Note: Command Error usually is generated by a Printer/Driver ink type mismatch. 1. Remove hubs and other devices on the USB bus. 2. Test the Printer using another Computer and Driver. 3. Verify that the Printer Driver reflects the correct ink type. 3.1 Access the Printer Driver from the Windows: Start: Settings: Printers and Faxes menu. 3.2 Access the Utility: Printer Option and Information section of the Driver and verify that the correct ink type is picked. 4. Reinstall the Printer Driver and Status Monitor 3. 5. Replace the Main Board. Command Error Printer Component, Software Item, LCD Display, Printer Button Page 113. Stylus Pro 4000 Field Repair Guide 4/28/05 Communication Errors PC Description: Status Monitor 3 reports a Communication Error. Reason: The Printer and the Driver / Computer are not communicating. Troubleshooting process: 1. Check the Printer’s Control Panel and verify. 1.1 The Printer is turned on. 1.2 The Printer is Ready (If the Printer displays Ink Out or a Service Required Error, the Printer is still ready). 1.2.1 The Printer is not Paused. 1.2.2 No Error Lights or messages on the LCD. 2. Check the Printer Driver. 2.1 Is the Printer set as the Default Printer. 2.1 Is the proper Port assigned to the Printer. 2.2 Does the Port see the Printer. 3. Check the Printer’s settings. 3.1 Is the Printer’s proper Interface enabled. 3.1.3 Communication Errors PC If the Interface is set to Auto, try setting the Port to the connected type. Printer Component, Software Item, LCD Display, Printer Button Page 114. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Send a test print from a simple application, such as Wordpad. 5. Verify the I/F Cable is working properly. 5.1 Reseat I/F Cable on both ends. 5.2 Verify that the I/F Cable is not excessively long (over 10 -15 feet) (Spec. is 10 feet). 5.3 Remove any HUBS or Switch Boxes from the Cabling. 5.4 Verify that the I/F Cable is not the problem. 5.4.1 Use another Cable or test the Cable with another Device. 5.5 If the Interface is Ethernet, verify that the Cable is: 5.5.1 A “straight through” Cable for most connections. 5.5.2 A “‘crossover” Cable for direct Computer to Printer connections. 6. Delete the Driver and reinstall. 7. Verify that the Port on the Computer is not the problem. 7.1 Use another device to test the Port on the Computer, or use another Computer. Other Considerations • Custom Dongles attached to RIP Servers could cause a problem. • Epson Printers use USB 2.0. Computer Ports that use USB 1.0, may cause a problem. • Status Monitor 3 can report an error on a Windows 2000 system, that does not exist. Turn off the Error Monitoring (Printer Driver: Utility: Speed & Progress: Monitoring Preferences Un-checked the Error box). Communication Errors PC Printer Component, Software Item, LCD Display, Printer Button Page 115. Stylus Pro 4000 Field Repair Guide 4/28/05 Cover Open Note: The Cover Open error indicates that the Printer’s Front Cover is open, or the Cover Sensor is defective. 1. The Cover Sensor can be tested in the Maintenance Mode 2: Self Testing: Test: Sensor menu. Cover Open Printer Component, Software Item, LCD Display, Printer Button Page 116. Stylus Pro 4000 Field Repair Guide 4/28/05 Drop of Ink Note: A Drop of Ink refers to ink dripping onto the media. Ink drips on the media come from two separate causes. The most common reason is a build up of ink on the nose of the Print Head. The second reason is a leak in the ink delivery system, in the Print Head area. Excessive ink build up on the Print Head Nozzle Plate is caused by problems with the Cap, Pump, Wiper Blades, and Wiper Blade Cleaner. Leaks in the ink delivery system (in the Print Head area), usually are caused by a bad connection between the Ink Supply Tube and the Damper. Sometimes a leaking Damper will cause the issue. Drop of Ink Printer Component, Software Item, LCD Display, Printer Button Page 117. Stylus Pro 4000 Field Repair Guide 4/28/05 Grainy or Ghosting Note: Grainey refers to an image that does not have smooth tonal transitions, or sharp resolution. Note: Ghosting refers to components of an image that are intended to be on top of each other (or adjacent) but are offset. Note: A low resolution image can me mis-diagnosed as Grainy. Grainey or ghosted images are usually caused by electronic or mechanical adjustments. The following is a list of adjustments that should be checked. • Print Head Slant Adjustment (CR) • Print Head Slant Adjustment (PF) • Auto Bi-D Adjustment [PG 1.2] • Auto Uni-D Adjustment Additionally the proper Print Head to media gap should be verified (Standard, Narrow, Wide, and Wider). The gap can be adjusted by performing the Platen Gap Adjustment. Intermittent or missing Nozzles may also be a factor. Non-Epson media or improper media settings in the driver can cause grainy images. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. The following components occasionally cause the issue. • Carriage Encoder • Carriage Encoder Strip • Carriage Motor • Carriage Belt Tension Grainy or Ghosting Printer Component, Software Item, LCD Display, Printer Button Page 118. Stylus Pro 4000 Field Repair Guide 4/28/05 Horizontal Banding Note: Horizontal Banding is either paper feed related, or Print Head related. Horizontal Banding is caused by vertical dot placement errors. Feed Related Feed related horizontal banding is always spaced at the same interval as the MicroWeave step. Observe the area of the image that is currently being printed (the image directly under the Print Head). That area exhibits the MicroWeave step. Compare the interval of the MicroWeave step with the interval of the horizontal banding. If the two have the same interval, the banding is probably feed related. Increase or decrease (increase or decrease to the extreme limit) the feed step and observe the impact on the banding. Use the Paper Config section of the driver, or Paper Config section of the Printer’s user menu, and increase or decrease the feed step all the way. If the banding is affected, it is feed related. If the banding is not changed, or a new banding is added, it is not feed related. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. Verify that the proper Spindle is being used (High Tension or Low Tension Spindle) Verify that the media does not bind coming off the roll. Print Head Related If the horizontal banding is Print Head related, it is usually due to missing, deflected or sympathetic Nozzles. the service level Nozzle Check, is the best way to inspect the Print Head’s accuracy. A slightly deflected Nozzle can cause horizontal banding, depending on the Nozzle’s location in the Nozzle array. Missing or deflected Nozzles may be caused by problems with the Cleaning Station. Before attempting to clear Nozzle issues, the Cap, Wiper Blade, Wiper Blade Cleaner, and the Print Head Nozzle Plate should be cleaned. Horizontal Banding Printer Component, Software Item, LCD Display, Printer Button Page 119. Stylus Pro 4000 Field Repair Guide 4/28/05 Additionally the Borderless Pads and Flushing Box should be checked to verify that they are not out of position or dirty. If a build up of contaminants makes contact with the Nozzle Plate, it will cause reoccurring Nozzle drop out. A Nozzle with a slight inaccuracy can cause horizontal banding. The M/W ADJ: feature located in the User Paper Config menu, is designed to change the Nozzle use pattern. Changing the Nozzle use pattern can minimize the frequency that a problem Nozzle is used, impacting the horizontal banding. Try all 3 settings (Standard, 1, and 2) and pick the best. Horizontal Banding Printer Component, Software Item, LCD Display, Printer Button Page 120. Stylus Pro 4000 Field Repair Guide 4/28/05 Missing Nozzle Diagnosis and Repair Note: Inspect the printer and media for dust or fiber accumulation. Excessive “dirt” will cause missing nozzles. Some Missing Nozzles, one or more colors 1. Check the Printer’s components for mechanical problems and “dirt”. 1.1 Clean Cap. 1.2 Check Wiper Blade for correct installation and flaws. 1.3 Clean Wiper Blade. 1.4 Clean the Nose of the Print Head. 1.5 Check the Borderless pads for proper installation and dirt. 1.6 Check the Flushing Box for dirt. 2. Puddle the Cap and park the Print Head for 30 minutes. 2.1 Fill the Cap with as much water as possible. 2.2 Park the Printhead on the Cap. 3. Perform 2 cleaning cycles. 3.1 Re-test the Nozzles. 3.2 Repeat step 3 if there is progress. 4. Replace the Print Head. All Nozzles Missing, One Color Only (The color comes back after a cleaning cycle, but drops out again) Missing Nozzle Diagnosis and Repair Printer Component, Software Item, LCD Display, Printer Button Page 121. Stylus Pro 4000 Field Repair Guide 4/28/05 1. Check the following components of the ink supply for a minor restriction, causing partial starvation. Note: Partial Starvation refers to a slight blockage of the ink supply system that slowly starves the Print Head for ink. 1.1 Remove corresponding Damper and attempt to draw ink with a syringe. The ink should draw easily. 1.1.1 If ink can not be drawn easily, remove Damper and attempt to draw ink through the Tube. If ink can be drawn easily, replace the Damper. 1.1.2 If Ink can not be drawn easily through the Tube, check the Ink Valve on the Cartridge Bay for correct operation. 1.1.3 If the Ink Valve is working properly, replace the Tube. All Nozzles Missing, One Color Only (The color does not comes back after a cleaning cycle) 1. Check the following components of the ink system for full starvation 1.1 Remove corresponding Damper and attempt to draw ink with a syringe. 1.1.1 If the Damper is empty, check for air leaks in the Tubes, Joints (O-rings and Fittings), or Dampers. 1.1.2 If ink can not be drawn, remove Damper and attempt to draw ink through the Tube. If ink can be drawn, replace the Damper. 1.1.3 If Ink can not be drawn through the Tube, check the Ink Valve on the Cartridge Bay for correct operation 1.1.4 If the Ink Valve is working properly, replace the Tube. All Nozzles Missing Note: Steps 1 and 2 must be run in sequence. 1. Check the Pump’s operation. 1.1 Run a cleaning cycle. Missing Nozzle Diagnosis and Repair Printer Component, Software Item, LCD Display, Printer Button Page 122. Stylus Pro 4000 Field Repair Guide 1.1.1 4/28/05 When the Printhead moves off of the Cap, and the Pump is running, inject water into the Cap with a syringe. 1.1.1.1 If the water is drawn through the Cap, the Pump is good. 1.1.1.2 If water is not drawn through the Cap, check the Pump Tube connections to the Cap. 1.1.1.3 If the Pump Tube connection is good, replace the Pump. 2. Check the Cap’s seal with the Printhead 2.1 Check the amount of ink in the Cap (it should be clean because of step 1). 2.2 Run a cleaning cycle 2.3 Check the amount of ink in the Cap (there should be clear signs of ink compared to step 2.1). 2.3.1 If there is no ink: 2.3.1.1 The Cap is not sealing with the Printhead. 2.3.1.1.1 Check the Cap Assembly for mechanical problems. 3. Check Printhead Fuses on Main Board. 3.1 If the Fuses are blown, replace the Main Board. 3.2 If the Fuses are good, replace the Printhead. Missing Nozzle Diagnosis and Repair Printer Component, Software Item, LCD Display, Printer Button Page 123. Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Jam Errors The Paper Jam Error indicates that one of the paper sensors does not detect paper properly. Roll Paper Test the following sensors using the Maintenance Mode 2: Self Testing: Test: Sensor menu • Rear Det (First Sensor in the roll paper path) • RearAD (Second Sensor in the roll paper path) Cut Sheet Paper from the Paper Cassette. Test the following sensors using the Maintenance Mode 2: Self Testing: Test: Sensor menu • P Det (First Sensor in the cut sheet path, located behind the Right Input Roller)(switch)) • RearAD (Second Sensor in the cut sheet path)(optical)) The RearAD Sensor can be calibrated using the Maintenance Mode 2: Self Testing: Adjustment: RearAD function. Paper Jam Errors Printer Component, Software Item, LCD Display, Printer Button Page 124. Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Not Cut Note: The Paper Not Cut error indicates that the Printer detected that the paper did not separate, after cutting. Paper cutting errors occur: •When the Cutter Blade is defective. •When the Cutter Blade does not have white nylon wheels. •When the Cutter Guide is damaged or out of position. •When the Cut Pressure is turned down too low. •When the paper is too thick (out of specification). Paper Not Cut Printer Component, Software Item, LCD Display, Printer Button Page 125. Stylus Pro 4000 Field Repair Guide 4/28/05 Reload Paper Note: The Reload Paper error indicates that the Printer recognizes paper in the Printer, but can not sense it’s size or location properly. The reload paper error can be generated if the paper is loaded beyond the alignment marks (paper loading alignment marks). The reload paper error can be generated if the paper width is a non-standard size. Always measure the paper and verify that it is the correct size. A 1/4” variance can generate the error. The reload paper error can be generated if the paper is skewed. A reload paper error can be generated if the user is trying to print borderless on an unsupported media size (width). Supported sizes: (8 , 8.3, 10, 12, 13, 14, 16, 17) 1. Verify that the Multi Sensor is working, and adjust it. The Multi Sensor measures the width, detects the leading edge, and measures the skew of the media. 1.1 Test the Multi Sensor using the Maintenance Mode 2: Self Testing: Test: Sensor menu 1.1.1 Test the EdgeAD 1.1.2 Test the Edge2AD 1.2 Adjust the Multi Sensor by performing the Multi Sensor Level adjustment. 2. Perform the T&B&S [Roll Paper] and/or T&B&S [Cut Sheet] adjustment. 3. Test the Carriage Encoder and Encoder Strip. The Carriage Encoder is used in conjunction with the Multi Sensor to measure the width of the media. 3.1 Test the Carriage Encoder and Encoder Strip using the Maintenance Mode 2: Self Testing: Test: Reload Paper Printer Component, Software Item, LCD Display, Printer Button Page 126. Stylus Pro 4000 Field Repair Guide 4/28/05 Encoder menu. Reload Paper Printer Component, Software Item, LCD Display, Printer Button Page 127. Stylus Pro 4000 Field Repair Guide 4/28/05 Random Nozzles Note: Random Nozzles refers to Nozzles that fire when they are not commanded to. Random Nozzle firing is caused by 1 of 4 components •Head Cables •Print Head •Main Board •Power Supply Head Cable Inspect the Head Cables for worn insulation. Place tape over the worn area or replace the Cable. Print Head or Main Board If the random Nozzle firing is caused by serial communication problems between the Main Board and the Print Head, the frequency of the random Nozzle firing changes when the printing resolution is changed. If changing the printing resolution affects the random Nozzle firing, change the Main Board and the Print Head. Change them one at a time in any order. Test between each change. Power Supply Sometimes (very rare) a noisy Power Supply causes random Nozzle firing. Random Nozzles Printer Component, Software Item, LCD Display, Printer Button Page 128. Stylus Pro 4000 Field Repair Guide 4/28/05 Scratch Note: A scratch is damage to the media surface caused by contact with a roller or other Printer components. Sometimes scratches occur before the media is inserted into the Printer. Some media is very sensitive to surface abrasions. Contact between the Pinch Rollers, the Paper Feed Roller, and the media is necessary to support and move it. If the media’s coating is too fragile, the Pinch Rollers (the Rollers that contact the media’s coating) can scratch the coating. Inserting the scratched media back into the paper path, and compare the location of the scratch on the media to adjacent rollers. Check the adjacent rollers for issues. Upgrade the 9 Plastic Rollers that scratch Smooth Fine Art Media loaded from the Paper Cassette. Follow the directions in the Plastic Roller Upgrade in the Field Guide. Scratch Printer Component, Software Item, LCD Display, Printer Button Page 129. Stylus Pro 4000 Field Repair Guide 4/28/05 Set Ink Cartridges Note: The Set Ink Cartridge error indicates that the Printer does not detected one or more Ink Cartridges. The error is usually generated when: •The Ink Cartridge Release Sensor is defective. •The Ink Bay CSIC Contacts are defective. •The Ink Cartridge CSIC Chip is defective. •The Cables to, or the Main Board is defective (least likely). Set Ink Cartridges Printer Component, Software Item, LCD Display, Printer Button Page 130. Stylus Pro 4000 Field Repair Guide 4/28/05 Set Ink Lever Note: The Set Ink Lever message indicates that the Ink Lever is in the up position, or that the Ink Lever Sensor is Defective. 1. Check the position of the Ink Cartridge Release Lever. 2. Check the operation of the Ink Cartridge Release Lever Sensor using the Maintenance Mode 2: Self Testing: Test: Sensor: InkLvr menu. Set Ink Lever Printer Component, Software Item, LCD Display, Printer Button Page 131. Stylus Pro 4000 Field Repair Guide 4/28/05 Smudge Note: A smudge is a mark left on the media by contact. It can be caused by contact with the Print Head, or contact with a dirty Roller. Dirty Roller A dirty Roller usually leaves a mark that repeats at an interval that is equal to the circumference of the Roller. Placing the image with the smudge back into the paper path, and aligning the smudge with the Printer’s Rollers will indicate which Roller is dirty. Print Head Most Print Head contact with the media is the result of the media curling up to meet the Print Head. It can also be caused by a build up of contaminants on the Print Head, that decrease the distance between the Print Head and the media. Sometimes the platen gap (the distance between the Print Head and the media) is set improperly. It can be incorrect because of user settings or because of incorrect measurement of the media thickness. Most media uses the Standard platen gap. The Standard platen gap is always one step back from the closest platen gap. If the platen gap is incorrect, the Paper Thickness Sensor should be checked, as well as the user platen gap settings found in the user menu. The Platen Gap can be calibrated using the Platen Gap Adjustment procedure. Smudge Printer Component, Software Item, LCD Display, Printer Button Page 132. Stylus Pro 4000 Field Repair Guide 4/28/05 Smear Note: A smear is caused by something “smearing” the intended image, after the image is printed. Many times smearing is a result of non-Epson media or ink. Non-Epson ink or media may dry to slowly, resulting in a smear after the image leaves the Printer. Adjusting the User Menu: Custom Paper: Drying Time: setting can slow down the Printer, allowing the image to dry properly. Inspect the image while it is being printed. Look for any component or object that is making contact with the image while the image is still in the Printer. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment over saturating the media. Smear Printer Component, Software Item, LCD Display, Printer Button Page 133. Stylus Pro 4000 Field Repair Guide 4/28/05 Vertical Banding Note: Vertical Banding is caused by horizontal dot placement errors. Saturation Related Vertical Banding If the vertical banding is caused by paper over saturation, the banding will correspond to rippling of the media. The rippling will be visible on the back of the media. This kind of vertical banding is usually about an inch wide. Under saturated images causes a type of vertical banding that is usually about 1/3 of an inch wide. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. Non-Epson drivers effect vertical banding if the amount of ink that is applied to the media is too low. Using the Epson driver should look better, if that is the case. Non-Epson media can impact vertical banding if the amount of ink that is required to correctly saturate the media is not applied by the Epson driver or a non-Epson driver. Alignment Related Vertical Banding Print an image in bi-directional mode, and in uni-directional mode (High Speed checked = bi-directional mode). If the vertical banding is more evident in bi-directional mode, the most likely cause is an improper Bi-D alignment. The Uni-D adjustment effects vertical banding in both bi-directional mode, and in uni-directional mode. Carriage Motor Related Vertical Banding If the vertical banding is more evident in uni-directional mode, the most likely cause is Carriage Motor vibration. Replacing the Carriage Motor may improve the banding. Vertical Banding Printer Component, Software Item, LCD Display, Printer Button Page 134. Stylus Pro 4000 Field Repair Guide 4/28/05 Wrong Ink Cartridge Note: The Wrong Ink Cartridge error indicates that the Printer detects an Ink Cartridge that does not match the Ink type expected. 1. Verify that the Maintenance Mode 2: Service Config: NPD value is set to the correct ink type. 2. Reset the Maintenance Mode 2: Service Config: NPD value. 2.1 Release the Ink Cartridges by raising the Ink Cartridge Release Lever. 2.2 Set the NPD value to 0. 2.3 Turn the Printer on, and lower the Ink Cartridge Release Lever. 2.4 The Printer will look at the Cartridge’s ink type and reset the Printer’s ink type to match. 3. The CSIC Contacts in the Ink Bay may cause this error. 4. A defective CSIC Chip or incorrect Ink Cartridge can cause the error. 4.5 Use the Maintenance Mode 1: CRTG INFO MENU: to look at the data on the CSIC Chip. Wrong Ink Cartridge Printer Component, Software Item, LCD Display, Printer Button Page 135. Stylus Pro 4000 Field Repair Guide 4/28/05 Adjustments Printer Component, Software Item, LCD Display, Printer Button Page 136. Stylus Pro 4000 Field Repair Guide 4/28/05 1000mm Feed Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the 1000mm Feed Adjustment. 1. Click on the Print button. 2. The Printer will print the 1000mm alignment pattern 3. Align a 1000mm ruler with the center vertical hash marks, and the leading edge horizontal line (see the Red Line on the example graphic). The “0” end of the 1000mm ruler should be touching, but not covering the leading edge horizontal line. 4. Use a lens to align the 1000mm ruler exactly with the horizontal and vertical lines. 5. Using a lens, measure the exact distance between the 2 horizontal lines. Be as accurate as possible 6. Enter the value that was measured. 5. Click on the Write button. 6. Click the Finish button. 1000mm Feed Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 137. Stylus Pro 4000 Field Repair Guide 4/28/05 Auto Bi-D Adjustment [PG 1.2] 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Auto Bi-D Adjustment. 1. Click on the Run button. 2. The Printer will print out these patterns. It will take approximately 15 minutes 3. The Printer will read the alignment patterns automatically (using the Multi Sensor), and write the appropriate values to the board. 4. Click the Finish button. Auto Bi-D Adjustment [PG 1.2] Printer Component, Software Item, LCD Display, Printer Button Page 138. Stylus Pro 4000 Field Repair Guide 4/28/05 Auto Uni-D Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Auto Uni-D Adjustment. 1. Click on the Run button. 2. The Printer will print out these patterns. It will take approximately 15 minutes 3. The Printer will read the alignment patterns automatically (using the Multi Sensor), and write the appropriate values to the board. 4. Click the Finish button. Auto Uni-D Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 139. Stylus Pro 4000 Field Repair Guide 4/28/05 Carriage Timing Belt Tension Adjustment 1. Remove the Left Side Cover. 2. Turn the Adjustment Screw until the Belt Bracket is positioned by the 3rd Mark from the right. Turn the Adjustment Screw. Carriage Timing Belt Tension Adjustment 3rd mark from the right. Printer Component, Software Item, LCD Display, Printer Button Page 140. Stylus Pro 4000 Field Repair Guide 4/28/05 Change Model Name Note: Change Model Name will write Stylus Pro 4000 to the Main Board (Plug and Play name) 1. From the Adjustment Wizard for the Pro 4000, select Change Model Name. 1. Click on Other. 2. Click on Run. 3. Click on Next Change Model Name Printer Component, Software Item, LCD Display, Printer Button Page 141. Stylus Pro 4000 Field Repair Guide 4/28/05 2. Click on Check to verify the current name. 1. Click on Check. Change Model Name 2. Verify the Printer is named Epson Stylus Pro 4000 Printer Component, Software Item, LCD Display, Printer Button 3. Click on Finished Page 142. Stylus Pro 4000 Field Repair Guide 4/28/05 Check Nozzle Note: Check Nozzle performs a user Nozzle Check. 1. From the Adjustment Wizard for the Pro 4000, select Check Nozzle. 1. Load paper. 2. Click on Run to print the pattern. The nozzle check pattern should look like this. 3. Click on Finish when done. Check Nozzle Printer Component, Software Item, LCD Display, Printer Button Page 143. Stylus Pro 4000 Field Repair Guide 4/28/05 Check Platen Gap Note: Check Platen Gap allows physical verification of the proper operation (setting) of the Platen Gap Detent Cam. 1. From the Adjustment Wizard for the Pro 4000, select Check Platen Gap. 1. Click on one of the 4 platen gap choices. 2. Click on Run. 3. Compare the position of the Platen Gap Detent Cam on the Printer against the corresponding graphic. 4. Click Finish when done. Check Platen Gap Printer Component, Software Item, LCD Display, Printer Button Page 144. Stylus Pro 4000 Field Repair Guide 4/28/05 Cleaning / Charging (Priming) Note: Cleaning explains the function of the various cleaning cycles accessed with the function keys. 1. From the Adjustment Wizard for the Pro 4000, select Cleaning. F5 forces a Prime. Cleaning / Charging (Priming) Printer Component, Software Item, LCD Display, Printer Button Page 145. Stylus Pro 4000 Field Repair Guide 4/28/05 Clear PF Micro Feed Adjustment [Bi-D] Note: The Clear PF Micro Feed Adjustment [Bi-D] resets the user paper feed adjustments that modifies the paper feed tables. It should be reset every time the Feed Length Adjustment is performed. 1. From the Adjustment Wizard for the Pro 4000, select the Clear PF Micro Feed Adjustment [Bi-D] 1. Click on Run. 2. Click on Finished. Clear PF Micro Feed Adjustment [Bi-D] Printer Component, Software Item, LCD Display, Printer Button Page 146. Stylus Pro 4000 Field Repair Guide 4/28/05 Copy Bi-D Variables Note: Copy Bi-D Variables transfers the data from the Manual Bi-D Adjustment at standard platen gap, to the memory locations that correspond to the other 3 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight times”. 1. From the Adjustment Wizard for the Pro 4000, select Copy Bi-D Variables. 1. Click on the 3 Check Boxes Copy Bi-D Variables 2. Click on Run. Printer Component, Software Item, LCD Display, Printer Button 3. Click on Finish Page 147. Stylus Pro 4000 Field Repair Guide 4/28/05 Copy Uni-D Variables Note: Copy Uni-D Variables transfers the data from the Manual Uni-D Adjustment at standard platen gap, to the memory locations that correspond to the other 3 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight times”. 1. From the Adjustment Wizard for the Pro 4000, select Copy Uni-D Variables. 1. Click on Run. 2. Click on Finish Copy Uni-D Variables Printer Component, Software Item, LCD Display, Printer Button Page 148. Stylus Pro 4000 Field Repair Guide 4/28/05 CR Encoder Sensor Position Adjustment Purpose: The Carriage Encoder Sensor Position Adjustment is used to ensure that the Carriage Encoder Timing Strip is centered in the Carriage Encoder Sensor across the entire length of the Printer Mechanism. 1. Sight down the Carriage Encoder Strip, and ensure that the Timing Strip is centered in the Carriage Encoder Sensor, at the 2 positions marked below. Check that the Strip is centered with the Carriage Encoder in this position (left position) Move the Left Side Encoder Strip Positioning Lever until the Strip is centered at the left position. CR Encoder Sensor Position Adjustment Check that the Strip is centered with the Carriage Encoder in this position (right position) Move the Right Side Encoder Strip Positioning Lever until the Strip is centered at the right position. Printer Component, Software Item, LCD Display, Printer Button Page 149. Stylus Pro 4000 Field Repair Guide 4/28/05 Head Rank ID Note: Enter the Head Rank ID before installing the Print Head. This way it is possible to enter the data directly off the Print Head. Otherwise, it is necessary to write down the data before installing the Print Head. 1. From the Adjustment Wizard for the Pro 4000, select the Head Rank ID. 1. Enter the Head Rank data located on the Print Head. 2. Click on the Write button. 3. Click on the Finish Button. Note: If the utility displays: “Incorrect Head Rank ID [QR Code] Input”, one or more of the digits entered is incorrect. Check that an O was not entered as a zero, etc. Head Rank ID Printer Component, Software Item, LCD Display, Printer Button Page 150. Stylus Pro 4000 Field Repair Guide 4/28/05 Initialize Main Board Note: Initialize Main Board will reset all settings. Do not use. 1. From the Adjustment Wizard for the Pro 4000, select Initialize Main Board. 1. Click on Run to reset all the settings on the Main Board. 2. Click on Finish when completed. Initialize Main Board Printer Component, Software Item, LCD Display, Printer Button Page 151. Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Discharge. Note: Ink Discharge allows the evacuation of the ink in the Tubes. 1. From the Adjustment Wizard for the Pro 4000, select Ink Discharge. 1. Remove the Ink Cartridges 2. Click on Run. 3. Click on Finish when completed. Ink Discharge. Printer Component, Software Item, LCD Display, Printer Button Page 152. Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Adjustment for Auto Nozzle Check 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Mulit Sensor Adjustment for Auto Nozzle Check. 1. Click on the Run button. 2. The Printer will print out these patterns. 3. The Printer will read the alignment patterns automatically (using the Multi Sensor), and write the appropriate values to the board. 4. Click on the Print Check Pattern button. 5. Click on the Run button. 6. The Printer will Print a check pattern, followed by a nozzle check pattern. 7. Click the Finish button. Multi Sensor Adjustment for Auto Nozzle Check Printer Component, Software Item, LCD Display, Printer Button Page 153. Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Auto PF Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Multi Sensor Auto PF Adjustment. 1. Click on Run. 2. The Printer will print a test pattern. (It takes about 15 minutes). While it is printing, it is reading the test pattern with the Multi Sensor and correctly setting the Feed Length Adjustment. 3. Click on Finish when completed. Multi Sensor Auto PF Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 154. Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Level Adjustment Note: This adjustment sets the “White Level” for the Multi Sensor (sensitivity calibration). 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Multi Sensor Level Adjustment 1. Click on the Run button. 2. The Printer will sample the paper with the Multi Sensor to set a reference level. 3. The Printer will print out the data that was written to the board. It will look like this. 4. Click the Finish button. Multi Sensor Level Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 155. Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Position Adjustment Note: This mechanical adjustment fixes the physical position of the Multi Sensor. 1. Rotate the Rear Carriage Rail until the Platen Position Stopper is in the first Detent. First Detent. 2. Place a 3mm feeler gauge on the Platen as shown. 3 mm feeler gauge. Multi Sensor Position Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 156. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Move the Multi Sensor over the thickness gauge. 1. Move the Multi Sensor over the thickness gauge. 2. Loosen 2 Screws and move the Multi Sensor in the direction of the arrows 3. Tighten the 2 Screws when the Multi Sensor gently touches the feeler gauge. Multi Sensor Position Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 157. Stylus Pro 4000 Field Repair Guide 4/28/05 Nozzle Bi-D Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Nozzle Bi-D Adjustment. 1. Click on the Print button. 2. The Printer will print out this pattern. 3. Inspect the pattern and identify the value that represents the most vertically straight line. It is possible to choose an odd number that would represent a value between the even printed 4. Enter the value from step 3 here. 5. Click the Write button. 6. Click the Finish button. Note: If none of the lines are straight, pick the line that is closest to straight, and write the value. Then reprint and try again. Each time the patterns should be closer. Repeat again if necessary, until there is a straight line. Pick and write that value. Nozzle Bi-D Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 158. Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Feed Timing Belt Adjustment 1. Remove the Left Side Cover. 2. Remove 2 Screws to free the Flexible Cable Support, and move it down, (out of the way). 1 Screw 1 Screw 3. Loosen the Screw that fastens the Paper Feed Motor Bracket, allowing the Tension Spring to Paper Feed Timing Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 159. Stylus Pro 4000 Field Repair Guide 4/28/05 apply tension to the Belt. Loosen this screw. This spring will apply tension to the belt. 4. Tighten the Screw, then check the Belt tension with your finger. There should be a deflection of approximately 1/8” to 1/16”. Press here. Look for 1/8’ to 1/16” deflection 5. If the Belt has too much deflection, loosen the Screw, and add some finger pressure to the Spring to increase the tension, and repeat step 4. Paper Feed Timing Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 160. Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Thickness Sensor Adjustment Purpose: The Paper Thickness Sensor Adjustment calibrates the Paper Thickness Sensor so that it correctly recognizes 3 different thickness ranges of media. The Paper Thickness Sensor does not measure the thickness of inserted media, it determines the “thickness range” of the media. Special Tools: The Paper Thickness Sensor Adjustment requires 4 flexible thickness gauges. 0.3mm 0.4mm 0.8mm 0.9mm 8.0” 3.0-” 1. Remove the Left, and Right Side Covers. 2. Re-install the Paper Release Lever Paper Thickness Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 161. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Remove the Top Cover. 4. Remove the Paper Thickness Sensor Cover. 1. Remove 3 Screws 2. Lift up, and off. 5. Press and hold the Left, Down, and Up buttons, and turn on the Printer (Maintenance Mode 2). 6. Using the Down button, navigate to Self Testing: Test: and press the Menu button. 7. Using the Down button, navigate to Test: Sensor: and press the Menu button. 8. Using the Down button, navigate to Sen: Paper 00 (May read 01, 10, or 11) Paper Thickness Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 162. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Insert the thickness gauges into the paper path as shown, and engage the pressure rollers (Paper Release Lever down). Insert thickness gauge as shown. 0 direction Right digit Left digit 1 direction 1. Insert the 4 gauges and check that the 3 conditions listed in step 9 are true. 2. If the conditions listed in step 10 are not true, loosen the fastening screws, and move the sensor positions until they are true. 10. The Paper Thickness Sensor should display the values listed below when the gauges listed below are inserted. 10.1 00 = When the 0.3mm thickness gauge is inserted. 10.1 01 = When the 0.4mm thickness gauge is inserted. 10.1 01 = When the 0.8mm thickness gauge is inserted. 10.1 11 = When the 0.9mm thickness gauge is inserted. Paper Thickness Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 163. Stylus Pro 4000 Field Repair Guide 4/28/05 Platen Gap Adjustment Purpose: The Platen Gap Adjustment sets the physical platen gap to the correct distance. 1. Remove the Left Side Cover. 1. Open the Top Cover, and defeat the Top Cover Sensor by wedging something (paper) against the Sensor. Wedge something against the Top Cover Sensor, to simulate a closed Top Cover. 2. Loosen the 2 Screws that fasten the Platen Gap Step Locking Mechanism, located on the left side of the Rear Carriage Rail. Loosen 2 Screws Platen Gap Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 164. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Press and hold the Left, Down, and Up buttons, and turn on the Printer (Maintenance Mode 2). 4. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button. 5. Using the Down button, navigate to ADJ: PG ADJ: and press the Menu button. 6. The Printer’s LCD will display [ENTER] Start. 7. Press the Menu button to start the procedure. 7.1 The Printer’s LCD will display Detecting Origin. 7.2 The Printer’s LCD will display PG Offset *(nn) (*nn = the current Platen Gap Offset). 8. Place a.65mm feeler gauge on the Platen as shown. 1. Slide the Carriage Assembly towards the feeler gauge. 2. Increase the Platen / Print Head gap by depressing the Up Arrow 3. Continue to increase the gap until the Print Head clears the.65mm feeler gauge. 4. Increase the Platen Gap Offset Value be 3 more steps than determined in step 3. Platen Gap Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 165. Stylus Pro 4000 Field Repair Guide 4/28/05 9. Place the Platen Position Detent device in the position shown below, and tighten the 2 Screws. Turn until the Stopper is resting in the first Detent (the detent has an arrow pointing at it). Tighten the 2 Screws. 10. Depress the Menu button to store the value. 10.1 The Printer will display Updating Parameter. Platen Gap Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 166. Stylus Pro 4000 Field Repair Guide 4/28/05 Platen Position Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Platen Position Adjustment. 1. Click on the Print button. 2. The Printer will print the alignment pattern 3. Measure the distance between the printed line, and the tab at the edge of the borderless printing pad as shown. Note: If the alignment mark is 1mm to the right of the tab at the edge of the borderless pad, the correct offset value would be 1. Note: If the alignment mark is 1mm to the left of the tab at the edge of the borderless pad, the correct offset value would be -1. 4. Enter the offset value. OK = Good NG = No Good 5. Click on the Write button. 6. Click the Next button. Platen Position Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 167. Stylus Pro 4000 Field Repair Guide 4/28/05 7. Click on the Check button. 8. The Printer will print and alignment check sheet. 9. Verify that the alignment marks are centered over the Borderless Printing Pads. (If they are not click on the Back button and repeat steps 1 - 5. OK = Good NG = No Good 10. Click on the Finish button. Platen Position Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 168. Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Slant Adjustment (CR) 1. From the Adjustment Wizard for the Pro 4000, select the Print Head Slant Adjustment (CR). 2. Move the Carriage to the position shown below, remove 3 Screws, and remove the Carriage Cover. Move the Carriage to Remove 3 Screws this position (align with the notch) Print Head Slant Adjustment (CR) Remove the Carriage Cover Printer Component, Software Item, LCD Display, Printer Button Page 169. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Loosen the 4 indicated Screws 1/4 turn. Loosen these 4 Screws 1/4 turn. 4. Move the Carriage back to the capped position. 5. Click on the Print Button, the alignment pattern will be printed. Print Head Slant Adjustment (CR) Printer Component, Software Item, LCD Display, Printer Button Page 170. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Using a lens, inspect the printed pattern. The pattern should look like this Move this lever down to rotate the Print Head clockwise. 7. Adjust, and reprint, until the alignment pattern is correct. 8. Tighten the 4 Screws, and reprint the pattern to verify that the pattern is still correct. 9. Re-install the Carriage Cover. Print Head Slant Adjustment (CR) Printer Component, Software Item, LCD Display, Printer Button Page 171. Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Slant Adjustment (PF) 1. From the Adjustment Wizard for the Pro 4000, select the Print Head Slant Adjustment (CR). 2. Move the Carriage to the position shown below, remove 3 Screws, and remove the Carriage Cover. Move the Carriage to Remove 3 Screws this position (align with the notch) Print Head Slant Adjustment (PF) Remove the Carriage Cover Printer Component, Software Item, LCD Display, Printer Button Page 172. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Loosen the 5 indicated Screws 1/4 turn. Loosen 1 Screw that fastens the Adjustment Lever Loosen 4 Screws that fasten the Print Head 4. Move the Carriage back to the capped position. 5. Click on the Print Button, the alignment pattern will be printed Print Head Slant Adjustment (PF) Printer Component, Software Item, LCD Display, Printer Button Page 173. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Using a lens, inspect the printed pattern. The Lever employs detentes to lock it in place. Flex the top portion of the Lever in the direction of the pivot point to release the detentes. The pattern should look like this. If the gap is larger at the top, pull the Lever down 7. Adjust, and reprint, until the pattern is correct. 8. Tighten the 5 Screws, and reprint the pattern to verify that the pattern is still correct. 9. Re-install the Carriage Cover. Print Head Slant Adjustment (PF) Printer Component, Software Item, LCD Display, Printer Button Page 174. Stylus Pro 4000 Field Repair Guide 4/28/05 RearAD Sensor Calibration Note: This adjustment sets the “White Level” for the RearAD Sensor (sensitivity calibration). Note: This adjustment can be performed using the customer’s media if it is non-standard (transparent, etc.). 1. Place paper in the paper path. Ensure that the paper is inserted past the Pinch Rollers and the Paper Feed Roller. 2. Press and hold the Left, Down, and Up buttons, and turn on the Printer (Maintenance Mode 2). 3. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button. 4. Using the Down button, navigate to RearAD: and press the Menu button. 5. The Printer’s LCD will display [ENTER] Start. Press the Menu button to start. 6. The Printer will sample the media setting the white level (sensor sensitivity). RearAD Sensor Calibration Printer Component, Software Item, LCD Display, Printer Button Page 175. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset ASF Counter Note: Reset ASF Counter is used to reset the Automatic Sheet Feeder counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset ASF Counter. 1. Click on Run to reset the ASF counter. 2. Click on Finish when done. Reset ASF Counter Printer Component, Software Item, LCD Display, Printer Button Page 176. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset Paper Ejection Switching Note: Reset Paper Ejection Switching is used to reset the Paper Exit Roller counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset Paper Ejection Switching. 1. Click on Run to reset the Paper Exit Roller counter. 2. Click on Finish when done. Reset Paper Ejection Switching Printer Component, Software Item, LCD Display, Printer Button Page 177. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset PF Motor Counter Note: Reset PF Motor Counter is used to reset the Paper Feed Motor counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset PF Motor Counter. 1. Click on Run to reset the Paper Feed Motor counter. 2. Click on Finish when done. Reset PF Motor Counter Printer Component, Software Item, LCD Display, Printer Button Page 178. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Cleaning Unit Change Note: Rest When Cleaning Unit Change is used to reset the Cleaning Unit counter. 1. From the Adjustment Wizard for the Pro 4000, select Check Nozzle. 1. Click on Run to reset the Cleaning Unit counter. 2. Click on Finish when done. Reset When Cleaning Unit Change Printer Component, Software Item, LCD Display, Printer Button Page 179. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When CR Unit Change Note: Reset When CR Unit Change is used to reset the Carriage Unit counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When CR Unit Change. 1. Click on Run to reset the Carriage Unit counter.. 2. Click on Finish when done. Reset When CR Unit Change Printer Component, Software Item, LCD Display, Printer Button Page 180. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Cutter Change Note: Reset When Cutter Change is used to reset the Cutter Solenoid life counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When Cutter Change. 1. Click on Run to reset the Cutter Solenoid life counter. 2. Click on Finish when done. Reset When Cutter Change Printer Component, Software Item, LCD Display, Printer Button Page 181. Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Print Head Change Note: Reset When Print Head Change is used to reset the Print Head life counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When Print Head Change. 1. Click on Run to reset the Print Head life counter. 2. Click on Finish when done. Reset When Print Head Change Printer Component, Software Item, LCD Display, Printer Button Page 182. Stylus Pro 4000 Field Repair Guide 4/28/05 RTC & USB & IEEE1394ID Adjustment 1. From the Adjustment Wizard for the Pro 4000, select the RTC & USB & IEEE1394ID Adjustment. Note: The order that is indicated by the following steps is important. The utility will not activate the Write button unless the proper order is observed. 1. Before entering any data, click on the Next button. RTC & USB & IEEE1394ID Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 183. Stylus Pro 4000 Field Repair Guide 4/28/05 2. Click on the Check button to display the IEEE1394 I.D. RTC & USB & IEEE1394ID Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 184. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Write down the IEEE1394 I.D. 4. Click on the OK button. 5. Click on the Back button. RTC & USB & IEEE1394ID Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 185. Stylus Pro 4000 Field Repair Guide 4/28/05 6. Verify that the Date and Time information is correct. It can be adjusted if necessary. 7. Enter the IEEE1394 I.D. 8. Enter the Printer’s serial number. 9. Click on the Write button to send the data to the printer. Note: The IEEE1394 I.D. is written on a label, that is located in the Main Board Cavity. RTC & USB & IEEE1394ID Adjustment Note: The IEEE1394 I.D. must be entered before the Printer’s serial number, for the Write button to be activated. Note: An IEEE1394 I.D. can be generated by using the following syntax: 0001EXXXX, where XXXX = the last 4 digits of the Printer’s serial number. Printer Component, Software Item, LCD Display, Printer Button Page 186. Stylus Pro 4000 Field Repair Guide 4/28/05 Skew Check 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Skew Check. 1. Click on the Run button. 2. The Printer will feed 1 meter of paper. 3. The Printer measure the amount of paper skew using the Multi Sensor, and display the results. 4. Click on the OK button. 5. Click the Finish button. Skew Check Printer Component, Software Item, LCD Display, Printer Button Page 187. Stylus Pro 4000 Field Repair Guide 4/28/05 T&B&S [Cut Sheet] Adjustment 1. Load A4 Enhanced Matte cut sheet paper. 2. From the Adjustment Wizard for the Pro 4000, select the T&B&S [Cut Sheet]. 1. Click on the Print button. 2. The Printer will print out this pattern, and measure the side margin using the Multi Sensor. 3. Measure the top (leading edge) margin, and enter the value measured. 4. Measure the bottom (trailing edge) margin, and enter the value measured. 5. Enter the side margin value printed on the print out, labeled “Side Margin Adjust”. 6. Click the Write button. 7. Repeat Steps 1 - 4. 8. Measure the side margin, and enter the value. 9. Click the Write button. 10. Click the Finish button. T&B&S [Cut Sheet] Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 188. Stylus Pro 4000 Field Repair Guide 4/28/05 T&B&S [Roll Paper] Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the T&B&S [Roll Paper]. 1. Click on the Print button. 2. The Printer will print out this pattern, and measure the Side Margin, the Multi Sensor Left, and the Multi Sensor Right values using the Multi Sensor. 3. Measure the top (leading edge) margin, and enter the value measured. 4. Measure the bottom (trailing edge) margin, and enter the value measured. 5. Measure the side margin (home position side), and enter the value measured. 6. Enter the Multi Sensor Left value printed on the print out, labeled “MS Left”. 7. Enter the Multi Sensor value printed on the print out, labeled “MS Right”. 8. Click the Write button. 9. Click the Finish button. T&B&S [Roll Paper] Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 189. Stylus Pro 4000 Field Repair Guide 4/28/05 Reference Printer Component, Software Item, LCD Display, Printer Button Page 190. Stylus Pro 4000 Field Repair Guide 4/28/05 Accessories List Sales Part Number Description C4000STAND Printer Stand C12C811171 2”/3”, 17” Normal Tension Media Spindle C12C811191 2”/3”, 17” High Tension Media Spindle C12C815291 Cutter Blade C12C824052 Multi-protocol 10/100 Base-T Type B Ethernet Interface Card C12C8890071 Maintenance Tank Accessories List Printer Component, Software Item, LCD Display, Printer Button Page 191. Stylus Pro 4000 Field Repair Guide 4/28/05 Cleaning Fluid Note: Cleaning fluid for the Pro 4000 is unique. It is an improved formula for pigmented ink. Part #: 1243924 Description: Cleaning Liquid Cartridge. Cleaning Fluid Printer Component, Software Item, LCD Display, Printer Button Page 192. Stylus Pro 4000 Field Repair Guide 4/28/05 Color Order on the Print Head User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Matte Black 2. Cyan 3. Magenta 4. Yellow 5. Photo Black 6. Light Cyan 7. Light Magenta 8. Light Black Color Order on the Print Head Printer Component, Software Item, LCD Display, Printer Button Page 193. Stylus Pro 4000 Field Repair Guide 4/28/05 Consumable/Service Parts List Ink is intended as a service tool (Warranty Service Only), and is not for sale. Use the Service Part Number, and claim it on a warranty form. Service Part # Sales Part # 110 ML (Pro 4000/7600/9600) ECCC Cost after 40% discount 1103969 T543100 UltraChrome Photo Black Warranty use only 1103970 T543200 UltraChrome Cyan Warranty use only 1103971 T543300 UltraChrome Magenta Warranty use only 1103972 T543400 UltraChrome Yellow Warranty use only 1103973 T543500 UltraChrome Light Cyan Warranty use only 1103974 T543600 UltraChrome Light Magenta Warranty use only 1103975 T543700 UltraChrome Light Black Warranty use only 1103976 T543800 UltraChrome Matte Black Warranty use only Service Part # Sales Part # 110 ML (Pro 4000/7600/9600) ECCC Cost after 40% discount 1103985 T545100 Dye Black (2 required) Warranty use only 1103986 T545200 Dye Cyan Warranty use only 1103987 T543300 Dye Magenta Warranty use only 1103988 T543400 Dye Yellow Warranty use only 1103989 T543500 Dye Light Cyan Warranty use only 1103990 T543600 Dye Light Magenta Warranty use only Consumable/Service Parts List Printer Component, Software Item, LCD Display, Printer Button Page 194. Stylus Pro 4000 Field Repair Guide 4/28/05 Service Part # Sales Part # Roll Paper ECCC Cost after 40% discount WAS041725 SO41725 Enhanced Matte 17” x 100’ roll $35.97 WAS041387 SO41387 Double Weight Matte 44” x 82’ roll $59.40 WAS041385 SO41385 Double Weight Matte 24” x 82’ roll $36.00 WAS041737 SO41737 Premium Luster Photo (250) 16” x 100’ roll $59.97 WAS041004 SP91004 Photo Semigloss 44” x 100’ roll $113.40 WAS041022 SP91022 Photo Semigloss 24” x 100’ roll $64.80 Maintenance Tank And 220 ml Ink Cartridges are available through Sales Channels only. Sales Part Number Description C12C8890071 Maintenance Tank Sales Part Number 220 ML (Pro 4000/7600/9600) T544100 UltraChrome Photo Black T544200 UltraChrome Cyan T544300 UltraChrome Magenta T544400 UltraChrome Yellow T544500 UltraChrome Light Cyan T544600 UltraChrome Light Magenta T544700 UltraChrome Light Black T544800 UltraChrome Matte Black Consumable/Service Parts List Printer Component, Software Item, LCD Display, Printer Button Page 195. Stylus Pro 4000 Field Repair Guide 4/28/05 Firmware History This chart explains the meaning of the firmware version characters. Stylus Pro 4000 Current Firmware Ver. I02552.upg Release date: 02/25/05 1. The Exit Roller setting was changed to minimize “Pizza Wheel” marks when printing on cut sheet paper and/or using the front manual feed. 2. The paper loading routine was modified to minimize Paper Jam errors with thin media, such as Firmware History Printer Component, Software Item, LCD Display, Printer Button Page 196. Stylus Pro 4000 Field Repair Guide 4/28/05 Tracing Paper, Single Weight Matte Paper, and Plain Paper. 3. The SSCL (Super Strong Cleaning Cycle) was modified to increase the ultrasonic portion of the cleaning cycle. The ultrasonic portion (strong piezo vibration) assists in disolving deposits on the nozzle plate. Additonally the SSCL was limited to 251 cleanings to protect the Print Head. Stylus Pro 4000 Firmware Ver. I02851.upg Release date:01/28/05 1. The firmware was modified to eliminate the clipping of images (top and bottom) when using RIP’s including ColorBurst. Stylus Pro 4000 Firmware Ver. I0154B.upg Release date:11/15/04 1. With earlier versions of firmware, at power up, a sheet may feed from the paper tray. With this version of firmware, a sheet is no longer fed at power up. Stylus Pro 4000 Ver. I0204A.upg Release date:10/20/04 1. This firmware version corrects centering issues at 1440 dpi on Single Weight Matte, Enhanced Matte, Photo Quality Ink Jet Paper, and Archival Matte sheet media. Stylus Pro 4000 Ver. IO2146.upg Firmware History Printer Component, Software Item, LCD Display, Printer Button Page 197. Stylus Pro 4000 Field Repair Guide 4/28/05 Release date: June 21, 2004 1. “Communication Errors” via a FireWire IEEE1394 connection under Mac OS X and Windows XP are corrected. 2. The message “DRIVER INK SETTING IS WRONG” is displayed if their is a mismatch between the printers panel ink setting and the driver setting. Previously a command error was reported. 3. To reduce noise when the printer is turned on, the fan on the main board is turned off. 4. “UNLOCK PRINT HEAD” is displayed before the initial ink charge if the carriage is locked. 5. Corrects the condition that resulted in a maintenance call “0080” (date and time not set) when the printer is first turned on. 6. Custom paper configuration can be enabled in the Driver or the printers Custom Paper Menu selection not both. 7. A paper size error no longer occurs when switching between manual feed and the paper cassette when the paper feed button is used. 8. The noise associated with loading Roll paper is reduced. 9. Nozzle loss caused by a print head cleaning is improved by a change to the print head cleaning process. 10. When the printer is idle the fan on the main board is turned off making the printer quieter. 11. Tracing paper media support improved. Firmware History Printer Component, Software Item, LCD Display, Printer Button Page 198. Stylus Pro 4000 Field Repair Guide 4/28/05 12. Corrects Service Request 00010007 (carriage motor timing) when the printer is powered on. 13. When loading media eliminates damage to the leading edge of the media. 14. The “Auto Nozzle Check” from the EPSON Service Utility 2 now functions correctly and ejects the media. 15. Ink smudges on the edges of the media are eliminated when performing border less printing. 16. The print head cleaning operation was modified to correct issues related to nozzle loss, air bubbles on the cap assembly, and cross color contamination. 17. Yellow now prints correctly at the right side of an image when the image size is 1.1mm wider then the media. 18. Horizontal banding is corrected for the following medias: Single weight Matte Paper, Photo Quality Ink Jet Paper, Premium Luster Photo Paper (250) Roll, Premium Luster Photo Paper (250) Cut sheet, and Premium Semimatte Photo Paper (250) Cut sheet by improvements made to the paper feed adjustment values for each media. Firmware History Printer Component, Software Item, LCD Display, Printer Button Page 199. Stylus Pro 4000 Field Repair Guide 4/28/05 19. An additional Yellow test pattern was added to the auto nozzle. 20. Erroneous paper eject service request 00010033 error is corrected by reducing chatter in the paper eject system. 21. The Dual CMYK ink set change function is removed. (Dual CMYK is not a supported model in the US) 22. Automatic Sheet Feeder service request message 00010031 is now reported correctly. 23. Auto nozzle check pattern, Auto Uni-d/Bi-d adjustment, Status sheet, and the Job information sheet print correctly on any size media. Firmware History Printer Component, Software Item, LCD Display, Printer Button Page 200. Stylus Pro 4000 Field Repair Guide 4/28/05 Firmware Update Procedure Note: This procedure is used to update or install firmware. It is the service method because it does not require the Printer to be “Online” to work. 1. Turn on the Printer while depressing the Up, Down, Left, and Right buttons. 1.1 The Printer will display UPDATE F/W 2. Using PRNPRINT.EXE transmit the current firmware to the Printer. 2.1 The Printer will display F/W Updating. 2.2 The Printer will display Update Complete. 2.3 The Printer will display Please Wait. 2.4 The Printer will re-initialize and display Ready. Firmware Update Procedure Printer Component, Software Item, LCD Display, Printer Button Page 201. Stylus Pro 4000 Field Repair Guide 4/28/05 Glossary Artifact A defect, that is within an image. It can mean something on the graphic that was not intended, or something missing that was intended. All image quality defects are artifacts. Bi-Directional Adjustment: An electronic adjustment, that ensures that a printer can coordinate left to right, with right to left, printing. Capped Position: The print head at it’s stand by position, with the cap mechanism sealing the nozzles. Coating: The top layer of graphics paper (media) that consists of a special substance designed to trap ink and keep it from being absorbed into the paper fibers. Non-paper based ink jet media uses coating to allow the ink to bond with the surface. A coatings purpose is to minimize dot gain, and control saturation. Color Shift: An unintended change of a gradient or tone. Continuous Tone: The qualities of a photograph that makes an image appear real. The smooth and lifelike transition from one color shade to the next, like in a photograph. Epson Ink Jet printers are not continuous tone printers. But when working properly, their printed images fool the human eye into seeing continuous tone transitions. Debris: A term that refers to unintended ink on the page deposited by debris dropping from the print head. Deflected Nozzle: A nozzle is firing, but the ink drop is not landing where it is intended too. Irregular spacing on the nozzle check pattern indicates this condition. Dithering: The dot pattern placed on the printed surface to create and image. Also known as screening. Dot Gain: A drop of ink tends to travel out from its point of impact, as the media absorbs it. The purpose of the coating (on the media) is to minimize dot gain. Glossary Printer Component, Software Item, LCD Display, Printer Button Page 202. Stylus Pro 4000 Field Repair Guide 4/28/05 Drop of Ink: Ink that appears to have dripped from the print head, or any other component of the ink supply. Dye Ink: Ink that colors the printed surface with dye. It is less durable than pigment ink, but has a wider color range (gamut). Electronic Alignments: Printer adjustments, which are performed using software routines that, allow the printer to compensate for physical variations in its mechanism. Error Diffusion: The type of dithering (screening) proprietary to Epson, that employs a random dot pattern to ensure that the human eye can discern no pattern. Flight Time: The time it takes a drop of ink to travel from the print head to the printable surface. Gamut: The range of colors that a printer can produce. Ghosting: A term that refers to components of an image that are intended to be on top of each other (or adjacent), but are offset. Gradient: A smooth transition between one color shade, and the next. A continuous tone image requires a smooth gradient for all its tonal shifts. Grainy: A breakdown of the “illusion of continuous tone”. A printed image that does not have smooth tonal transition, and sharp detail. Head Angular Adjustment: A term that refers to a mechanical print head alignment that ensures that an ink jet’s print heads nozzles are on the same vertical plane. (Also known as the B head slant or the C head slant.) The head is rotated until it is vertically linear. Glossary Printer Component, Software Item, LCD Display, Printer Button Page 203. Stylus Pro 4000 Field Repair Guide 4/28/05 Head Gap Adjustment: An electronic print head adjustment that ensures that the printer knows the exact distance between nozzle sets on separate heads. Also known as Head L/R and Uni-Di... Head ID: The calibration value written on the print head that allows the printers electronics to compensate for the print heads “personality” (inaccuracies). Head Linear Adjustment: A mechanical print head alignment that ensures that on a two-head ink jet printer that all the nozzles are on the same horizontal plane. (Also known as Head Height and BC Head Slant.) The right head is moved in relation to the left head. Home Position: The print head’s horizontal reference position, as determined by the Home Position Sensor Horizontal Banding: An image defect that extends from the left, to the right margin (parallel to the direction of print head movement). The defect could be a lighter or darker “band” than is intended. It usually repeats, with the same interval, from the top margin to the bottom.). Horizontal Over-lap: A type of horizontal banding, where multiple print head passes overlap while printing. The banding looks darker than the intended image. Multiple passes of the print head should place ink on the paper next to, but not on top of earlier passes. Glossary Printer Component, Software Item, LCD Display, Printer Button Page 204. Stylus Pro 4000 Field Repair Guide Horizontal Under-lap: 4/28/05 A type of horizontal banding, where multiple print head passes have a space between them. The banding looks lighter than the intended image. Multiple passes of the print head should place ink on the paper exactly next to earlier passes with no space in between. Illusion of Continuous Tone. A term that refers to “fooling” the human eye into perceiving a dot matrix image as a photograph (continuous tone image). Epson ink jet printers are not continuous tone printers. However, when working properly, their printed images fool the human eye into seeing continuous tone transitions Ink Color Contamination: The intended color of the ink supply has been altered. Ink Impurities: Foreign objects in the ink supply. Margin Shift: A term that refers to an image with irregular right and left side margins. Mechanical Alignments: Printer adjustments, that requires physically moving parts of the mechanism. Media: The surface that is being printed on, usually paper. Metamerism: The different appearance of colors caused by different light sources and viewing angles Micro Weave: The way an Epson Ink Jet printer interlaces (weaves) bands of and image during printing. Moiré Pattern: A repetitive pattern, within an image, which is not intended. I can appear like a paisley or herringbone pattern. Over Saturation: Too much ink has been applied to the printable surface for the media to support. Paint Brush Effect: Something horizontally across the printed surface, that was not intended. Usually caused by an ink soaked fiber hanging off the print head. Pigment Ink: Ink that deposits colored particles (pigment) on the printed surface to create an image. It is more durable than dye based ink, but does not have as wide a color range (gamut). Glossary Printer Component, Software Item, LCD Display, Printer Button Page 205. Stylus Pro 4000 Field Repair Guide 4/28/05 Pixilated: An image quality issue that is caused by a low-resolution image printed at high resolution. Platen Gap: The distance between the print head, and the printable surface. Rippling: A term that refers to a condition caused by over saturated paper warping. Saturation: The amount of ink applied to the printed surface. Screening: The dot pattern placed on the printed surface to create and image. Also known as dithering. Skew: Crooked paper in the printer. Smear: An image that has been rubbed by something, causing it to be deformed, or smeared. The direction or any repetition of the smear should be noted. Smudge: Something on the printed surface, that was not intended. Usually transferred to the page because of contact with a dirty roller or the print head. Any repetition should be noted and measured. Sublimation Ink: Ink that is first printed on thermal transfer media, and then transferred using heat to another surface. Sympathetic Nozzle: A nozzle that is not intended to fire, firing in conjunction with an intended nozzle. Tone: The specific shade of a color. Under Saturation: Not enough ink has been applied to the printable surface to properly saturate the media. UN-sharp: “Fuzzy “qualities in an image usually caused by too much dot gain. Vertical Banding, Irregular: Vertical bands perpendicular to the direction of print head movement, that are not linear. Usually created by paper “rippling”, caused by over saturation. Glossary Printer Component, Software Item, LCD Display, Printer Button Page 206. Stylus Pro 4000 Field Repair Guide 4/28/05 Vertical Banding, Linear: An image defect that extends from the top, to the bottom margin (perpendicular to the direction of print head movement). It usually repeats, with the same interval, from the left margin to the right. White Specks: A term that indicates that the intended image has small missing areas where no ink has been deposited. Glossary Printer Component, Software Item, LCD Display, Printer Button Page 207. Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Draining Procedure 1. Press and hold the Left, Down, and Up buttons, and turn on the Printer (Maintenance Mode 2). 2. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button. 3. Using the Down button, navigate to ADJ: Ink Drain: and press the Menu button to start the procedure. 4. Follow the directions displayed by the Printer’s LCD. Ink Draining Procedure Printer Component, Software Item, LCD Display, Printer Button Page 208. Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Tube Order Note: This chapter documents the order that the Ink Tubes are connected to the Print Head. The Ink Tube/Print Head color order is listed left to right. 1. Light Black 2. Light Magenta 3. Light Cyan 4. Photo Black 5. Matte Black 6. Cyan 7. Magenta 8. Yellow User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Matte Black 2. Cyan 3. Magenta 4. Yellow 5. Photo Black 6. Light Cyan 7. Light Magenta 8. Light Black Ink Tube Order Printer Component, Software Item, LCD Display, Printer Button Page 209. Stylus Pro 4000 Field Repair Guide 4/28/05 Prime, On or Off Prime, Initial Fill, and Charge mean the same thing. They all refer to filling the Ink System with ink. Controlling the Prime function requires Setting, or Resetting the Init.Fill Flag. Init.Fill: Reset = The Printer is already primed. Init.Fill: Set = the Printer will prime the next time it is turned on. 1. Turn on the Printer while depressing the Left, Up, and Down buttons. The Printer will display SELF TESTING. 2. Press the Right button once. The Printer will display SELF TESTING: Test. 3. Press the Down button until the Printer displays SELF TESTING: Parameter. 4. Press the Right button once. The Printer will display Parameter: Initialize. 5. Press the Down button once. The Printer will display Parameter: Update. 6. Press the Right button once. The Printer will display Update: InkParameter. 7. Press the Right button once. The Printer will display Init.Fill: Set. 7.1 Press the Down button to change between Init.Fill: Set, and Init.Fill: Reset. 8. Press the Right button once. The Printer will display Update Param.?. 9. Press the Right button once. The Init.Fill flag will be set. Prime, On or Off Printer Component, Software Item, LCD Display, Printer Button Page 210. Stylus Pro 4000 Field Repair Guide 4/28/05 Revision History April 28, 2005 The Firmware History chapter was updated. April 1, 2005 1. 24 troubleshooting chapters were added. 2. A chapter listing service tool part numbers was added. 3. A chapter listing accessory part numbers was added. March 17, 2005 1. Parameter Backup mode directions were added to the Control Panel Map chapter. 2. A chapter titled Consumable/Service Parts List was added to provide service part #’s for ink and media. January 7, 2005 1. Initial release. Revision History Printer Component, Software Item, LCD Display, Printer Button Page 211. Stylus Pro 4000 Field Repair Guide 4/28/05 Sensors, Motors, Solenoids, and Fans 1. Home Position Sensors: Carriage HP Sensor (CR Origin) Gap HP Sensor (Head Slide) Pump HP Sensor(Pump) Exit Roller HP Sensor (POUT) ASF Roller HP Sensor Maintenance/Waste Ink Tank Sensor Waste Ink ID (CSIC) (MainteTank) Ink Cartridge Sensors: Cartridge CSIC’s (Customer Satisfaction Ink Cartridge (8) Ink Cartridge Lock Lever Sensor (2)(Ink Lever) Encoders: Carriage Encoder Paper Feed Encoder Paper Sensors: Manual Feed Sensor (Rear Det) Paper Empty Sensor (RearAD) Multi Sensor (EdgeAD) (Edge2AD)(Width, Leading Edge, Nozzles, Alignments) Paper Thickness Sensor (Paper)(Lever)(also registers paper release)(2 Sensors) ASF Input Sensor (P Det) Safety Sensors: Top Cover Sensor(Cover) Rear Cover Sensor(Rear Guide) Exit Roller Customer Safety Sensor Temperature Sensors: Head Temperature Sensor (Head Temp) Head Driver Temperature Sensor (Drv Temp) Sensors, Motors, Solenoids, and Fans Printer Component, Software Item, LCD Display, Printer Button Page 212. Stylus Pro 4000 Field Repair Guide 4/28/05 2. Motors Carriage Motor Paper Feed Motor: turns the Paper Feed Roller, Sub Roller and the Eject Roller Pump Motor: also turns the Input Roller Platen Gap Motor: also sets the Eject Roller position, the Sub Platen Rib position, releases and engages the Pressure Rollers for the Sub Roller. Solenoids Cutter Blade Solenoid Fans Head Drive Cooling Fan Paper Suction Fans (2) Sensors, Motors, Solenoids, and Fans Printer Component, Software Item, LCD Display, Printer Button Page 213. Stylus Pro 4000 Field Repair Guide 4/28/05 Service Procedure 1. Observe the customer’s service issue. 2. Update the firmware to the current version if necessary. 3. Repair the customer’s service issue. 4. Clean the Carriage Rails with a dry cloth or paper towel 5. Clean the Cap, Wiper Blade, and Wiper Blade Cleaner. 5.1 Clean the Print Head Nozzle Plate if necessary. 5.1.1 Loosen the Carriage Belt 5.1.2 Remove the Carriage Mechanism and clean. 6. Clean and check the Borderless Pads. 7. Blow off the Multi Sensor 8. Check the Print Head’s mechanical alignments 8.1 Perform the Print Head Slant Adjustment (CR) 8.2 Perform the Print Head Slant Adjustment (PF) 9. Perform the Multi Sensor Level Adjustment. 10. Perform the Multi Sensor Adjustment for Auto Nozzle Check. 11. Perform the Clear Micro Feed PF Adjustment (Bi-D) Service Procedure Printer Component, Software Item, LCD Display, Printer Button Page 214. Stylus Pro 4000 Field Repair Guide 4/28/05 12. Perform the 1000 mm Feed Adjustment, or Multi Sensor Auto PF Adjustment. 13. Perform the Nozzle Bi-D Adjustment 14. Perform the Auto Bi-D Adjustment 14.1 Perform Copy Bi-D variables 15. Perform the Auto Uni-D Adjustment 15.1 Perform Copy Uni-D variables 16. Perform T&B&S [Roll Paper] and/or T&B&S [Cut Sheet] adjustment. 17. Perform Reset When CR Unit Change. 18. Perform Reset When Cleaning Unit Change. Service Procedure Printer Component, Software Item, LCD Display, Printer Button Page 215. Stylus Pro 4000 Field Repair Guide 4/28/05 Service Tools Service Part Number Description 1243924 Cleaning Liquid Cartridge (Requires 8 Cartridges) 1047746 1000 mm Scale (meter stick) 1282354 Multi Sensor Position Tool 1282355 Paper Thickness Sensor calibration tools 1080614 G-26 Grease 1039172 G-46 Grease Service Tools Printer Component, Software Item, LCD Display, Printer Button Page 216. Stylus Pro 4000 Field Repair Guide 4/28/05 Stress Test (Test Image) Purpose: The Printer Stress Test was designed to amplify any print quality issues. It is for diagnosis purposes only. It never looks perfect. There is always some horizontal and vertical banding. Use: 1. Use it to compare Non-Epson Drivers against the Epson Driver. 2. Use it to look for image quality variances across the entire printable area of the printer. Is the vertical banding consistent across the entire image? Is the horizontal banding consistent across the entire image? Is the density consistent across the entire image? If the answer to any of the above questions is no, Contact Epson. It may be a parallelism issue. Stress Test (Test Image) Printer Component, Software Item, LCD Display, Printer Button Page 217. Stylus Pro 4000 Field Repair Guide 4/28/05 User Nozzle Check Order User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Matte Black 2. Cyan 3. Magenta 4. Yellow 5. Photo Black 6. Light Cyan 7. Light Magenta 8. Light Black User Nozzle Check Order Printer Component, Software Item, LCD Display, Printer Button Page 218. Stylus Pro 4000 Field Repair Guide 4/28/05 Utilities Printer Component, Software Item, LCD Display, Printer Button Page 219. Stylus Pro 4000 Field Repair Guide 4/28/05 Adjustment Wizard2 Note: The Adjustment Wizard is the utility that enables electronic and mechanical alignments of the Pro 4000. 1. Ensure that the Pro 4000 Printer Driver and Status Monitor 3 is installed on the system that will be running the Adjustment Wizard2. 2. Create a folder and copy the Adjustment Wizard 2 files into it. 3. Double Click on Adjwiz2 to start the utility. Adjustment Wizard2 Printer Component, Software Item, LCD Display, Printer Button Page 220. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Pick the correct printer driver/port, 8 Color, Individual, and click Start. Printer Driver and Port. 8 color Individual Start Adjustment Wizard2 Printer Component, Software Item, LCD Display, Printer Button Page 221. Stylus Pro 4000 Field Repair Guide 4/28/05 5. The utility will look like this. 6. Double click on the individual line items to perform each adjustment. Adjustment Wizard2 Printer Component, Software Item, LCD Display, Printer Button Page 222. Stylus Pro 4000 Field Repair Guide 4/28/05 Epson Paper Feed Adjuster Note: The Epson Paper Feed Utility is a user utility designed to customize the Printer, to increase it’s print quality. Technicians can use it to reset user settings. Ensure that the Pro 4000 Printer Driver and Status Monitor 3 is installed on the system that will be running the Adjustment Wizard2. Installation: 1. Double click on Setup to launch the installer. Double Click on Setup 2. Follow the prompts, and install the Epson Paper Feed Adjuster on your computer. After it is installed, it will run from the Window’s Start Menu. Epson Paper Feed Adjuster Printer Component, Software Item, LCD Display, Printer Button Page 223. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Run the Epson Paper Feed Adjuster from the Windows Start Menu. 1. Click On Initialize Adjustment Values. 2. Click on OK. Epson Paper Feed Adjuster Printer Component, Software Item, LCD Display, Printer Button Page 224. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Click on Initialize. 4. Click on OK. Epson Paper Feed Adjuster Printer Component, Software Item, LCD Display, Printer Button Page 225. Stylus Pro 4000 Field Repair Guide 4/28/05 NVRAM.EXE Note: NVRAM.EXE is the utility that enables the backup and re-installation of parameters (settings), necessary when exchanging the Main Board of a Pro 4000. Installation: 1. Ensure that the Pro 4000 Printer Driver and Status Monitor 3 is installed on the system that will be running the NVRAM.EXE. 2. Create a folder and copy the NVRAM.EXE files into it. 3. Double Click on NVRAM to start the utility. 4. Place the Printer in Parameter Backup Mode 1. Enter Maintenance Mode 2: Press and hold the Left, Down, and Up buttons and turn on the Printer 2. Lift both (2) Ink Levers 3. Remove the Maintenance Tank 4. Move the Paper Release Lever to the released position. NVRAM.EXE Printer Component, Software Item, LCD Display, Printer Button Page 226. Stylus Pro 4000 Field Repair Guide 4/28/05 Parameter Backup:. 1. Pick the Pro 4000 printer driver. The port that the driver is associated with, will be displayed. 3.Click on Read. The Printer LCD will toggle between Ready and Printing. The utility will display this, until it is finished transferring data. 4. Click on Save to save the parameters. NVRAM.EXE Printer Component, Software Item, LCD Display, Printer Button Page 227. Stylus Pro 4000 Field Repair Guide 4/28/05 Parameter Restore. 1. Pick the Pro 4000 printer driver. The port that the driver is associated with, will be displayed. 3.Click on Write to send previously loaded Parameters to the Printer. (If the Parameters are not loaded, click on Open and load saved Parameters, then click on Write. The utility will display this screen while it is transmitting the Parameters to the Printer. Do not turn the printer off until the utility displays this screen. NVRAM.EXE Printer Component, Software Item, LCD Display, Printer Button Page 228. Stylus Pro 4000 Field Repair Guide 4/28/05 PRNprint.exe Note: PRNprint.exe is the utility that is used to copy Firmware to the Printer. 1. Ensure that the Pro 4000 Printer Driver is installed on the system that will be running the PRNprint.exe. 1. Double Click on PRNprint to start the utility. 2. Click on Open. 1. Click on Open PRNprint.exe Printer Component, Software Item, LCD Display, Printer Button Page 229. Stylus Pro 4000 Field Repair Guide 4/28/05 3. Select the correct firmware and load it into the utility. 1.Change the file type to All Files 2. Navigate to, and click on the correct firmware file. 3. Click on Open PRNprint.exe Printer Component, Software Item, LCD Display, Printer Button Page 230. Stylus Pro 4000 Field Repair Guide 4/28/05 4. Send the firmware to the Printer. 1. Select the correct printer driver. 2. Click on Print. PRNprint.exe Printer Component, Software Item, LCD Display, Printer Button Page 231.
